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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. Do not use a replacement
part of iesser quality.
To help avoid accidental air bag deployment and personal injury, when
servicing a vehicle that requires repair of the SIR system and another
vehicle system, it is recommended that the SIR system be repaired first
using service manual procedures.
FOREWORD
This manual contains procedures for disassembly and assembly of the components listed in the table of contents
once they have been removed from the vehicle. Procedures explaining how to remove components from the vehicle
are outlined in the specific vehicle service manual. Driveability and Emissions system information, and Electrical
System diagnosis are published in the specific vehicle Driveability, Emissions, and Electrical Diagnosis manual.
This manual should be kept in a handy place for ready reference. If properly used, it will meet the needs of
technicians and vehicle owners.
ifl
CAUTION: General Motors service manuals are intended for use by professional, qualified
technicians. Attempting repairs or service without the appropriate training, tools, and
equipment could cause injury to you or others and damage to your vehicle that may cause
it not to operate properly.
1995
LIGHT DUTY TRUCK
UNIT REPAIR MANUAL
The Table of Contents on the following page indicates the sections covered in this manual. At
the beginning of each individual section, a Table of Contents page gives the number on which
each major subject begins.
When reference is made in this manual to a brand name, number, or specific tool, an
equivalent product may be used in place of the recommended item.
All information, illustrations, and specifications contained in this manual are based on the latest
product information available at the time of publication approval. The right is reserved to make
changes at any time without notice.
GMT/95-LUR
©1994 General Motors Corporation April 1994
Printed in U.S.A. All rights reserved
No part of this publication may be reproduced, stored in any retrieval system, or transmitted, in
any form or by any means, including but not limited to electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of General Motors Corporation. This
includes all text, illustrations, tables, and charts.
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.
If you find an error, omission, or have a suggestion on • Vehicle Identification Number of vehicle being
any General Motors Service Manual, we want to hear worked on.
from you. • Section and page number(s)
• Description of problem
United States and Canada (General Motors Dealer
Employees Only)— This phone number cannot provide Technical Assis
1-800-828-6860 tance. Contact your regular Technical Assistance
8:00 AM to 5:00 PM Eastern Time Zone source.
Canada, French Speaking— The personnel answering this phone number will pro
(General Motors Dealers Employees Only) vide the author of the information with your comments
1-800-503-3222 and will follow up until an answer is given.
8:30 AM to 5:00 PM Eastern Time Zone
If you wish to send examples or marked-up pages, the
These phone numbers can be called Monday through person who takes your call will tell you how to do that.
Friday. Be prepared to give the following information:
United States and Canadian Vehicle Owner or Oper
• Your name ator:
• Your dealership’s name If you are the owner or operator of the vehicle, please
• Your phone number give your comments to the Customer Assistance Cen
• Model year and vehicle line tre. The phone number and address are in your Own
• Publication book number (if present) er’s Manual.
GM I ServiceTechnology Group
v
':' ?
•8TV3MM00 JAUWAM 30IVFB3 3fJ0T0f,!! JAR3W30
■
GENERAL INFORMATION OA-1
SECTION OA
GENERAL INFORMATION
CONTENTS
SUBJECT PAGE
Special Tool Ordering Information................................................... 0A-1
GM Service Manual Comments......................................................... 0A-1
Service Parts Identification Label.................................................... 0A-1
Vehicle Identification Number............................................................ OA-2
Vehicle Certification Label................................................................. OA-2
Engine Identification Number........................................................... . OA-3
Transmission Identification Number............................................... . OA-3
Metric Fasteners................................................................................... OA-3
Fastener Strength Identification........................................................ OA-5
Prevailing Torque Fasteners............................................................. . OA-5
J1930 Word Conversion..................................................................... OA-6
□ c
HU
GAWR FRT
LB/K G
SPEED
RTG PSI/K PA (COLD)
□
□
CD
SEE OWNER'S MANUAL FOR ADDIT ION AL INFORMATION
ENGINE IDENTIFICATION
NUMBER
METRIC FASTENERS
The VIN provides engine identification information by
liter and by the engine code letter located on the vehi Current model GM vehicles are primarily dimensioned
cle identification plate. in the metric system. Many fasteners are metric and are
All engines are stamped with an engine identification very close in dimension to well-known customary fas
number. Refer to figures 5, 6, 7, 8, and 9 to determine teners in the inch system. Replacement fasteners must
the engine identification number location. be of the correct nominal diameter, thread pitch, and
Additionally, stick-on labels attached to the engine, or strength.
laser etching or stampings on the engine block, indicate Original-equipment metric fasteners (except “beauty”
the engine unit number and date code. bolts, such as exposed bumper bolts, and cross-recess
head screws) are identified by a number of markings
indicating the strength of the material in the fastener.
TRANSMISSION Metric cross-recess screws are identified by a Posidriv
IDENTIFICATION NUMBER or Type 1A. Either a Phillips head or Type 1A cross-re-
cess screwdriver can be used in Posidriv recess screw
Refer to figures 10 through 14 to determine transmis
heads, but Type 1A cross-recess screwdrivers will per
sion identification numbers and code.
form better.
OA-4 GENERAL INFORMATION
Figure 7—5.0L, 5.7L Engine I.D. Location Figure 8—7.4L Engine I.D. Location
VIEW B
FASTENER STRENGTH
IDENTIFICATION
Most commonly used metric fastener strength proper
ly classes are 9.8 and 10.9 with the class identification
embossed on the head of each bolt. Some metric nuts
will be marked with single digit strength identification
numbers on the nut face.
When replacing metric fasteners, use bolts and nuts
of the same strength or greater than the original fasten
ers (the same number marking or higher). Likewise, it is
important to select replacement fasteners of the correct
size. Correct replacement metric fasteners available in
the aftermarket parts channels were designed to metric
standards of countries other than the United States, and
may be of a lower strength, may not have the num Figure 10— Borg Warner T-5 Transmission I. D.
bered head marking system, and may be of a different Location
thread pitch. The metric fasteners used on GM products
Recommendations For Reuse:
are designed to international standards that may not yet
be manufactured by some non-domestic bolt and nut 1. Clean, unrusted, prevailing torque nuts and bolts
suppliers. may be reused as follows:
A. Clean dirt and other foreign material off the nut
PREVAILING TORQUE or bolt.
B. Inspect the nut or bolt to ensure there are no
FASTENERS cracks, elongation, or other signs of abuse of
A prevailing torque nut develops an interference overtightening. (If there is any doubt, replace
between the nut and bolt threads. This is most often with a new prevailing torque fastener or equal
accomplished by distortion of the top of an all-metal nut or greater strength.)
by using a nylon patch on the threads in the middle of C. Assemble the parts, and hand start the nut or bolt.
the hex flat. A nylon insert may also be used as a D. Observe that, before the fastener seats, it
method of interference between nut and bolt threads. develops the proper torque. (If there is any
A prevailing torque bolt develop an interference doubt, replace with a new prevailing torque fas
between bolt and nut threads, or the threads of a tener of equal or greater strength.)
tapped hole. This is accomplished by distorting some of E. Tighten the fastener to the torque specified in
the threads or by using a nylon patch or adhesive. the appropriate section of this manual.
£
NEW VENTURE GEAR
3500 (5LM60)
BUILD MONTH
A - JANUARY
B - FEBRUARY
REBUILD MONTH
USED ONLY WHEN CASE
IS REUSED - SAME
C - MARCH CODING AS 3RD DIGIT
D - APRIL
E -M A Y
H -J U N E
K -JU LY
M - AUGUST
P - SEPTEMBER
R - OCTOBER
S - NOVEMBER
T - DECEMBER
VIEW A
J1930 WORD
CONVERSION
Starting with the 1993 model year, General Motors
will be complying with the Society of Automotive Engi
neers (SAE) Recommended Practice J1930. J1930 is
an industry wide standard that was adopted into gov
ernment regulations. It requires certain electrical and
electronic components and systems be known by the
same nomenclature that have the same function. This
standard is also being applied to abbreviations and
acronyms. This standard is being used in all GM ser
vice publications.
To make this standard work, some names and abbre
viations are being replaced with those recommended by
Figure 13— Hydra-Matic 4L60-E Transmission I. D. the SAE standard.
Location For determining J1930 word conversions, refer to fig
ure 15.
HYDRA-MATIC
TRANSMISSION I.D. [m o d e l ! 4L80-E / 4L80-EHD
NAMEPLATE
LOCATION
,0 ,0 0 0
SECTION 1
AIR CONDITIONING
CONTENTS
SUBJECT PAGE
HR100T/HR110-MD Air Conditioning Compressor.............................................................................................. 1D1-1
HD-6/HR6-HE Air Conditioning Compressor........................................................................................................1D2-1
V-5 Air Conditioning Compressor........................................................................................................................... 1D3-1
SD-7H15 Air Conditioning Compressor................................................................................................................ 1D4-1
---------------- —— —
NOTES
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r-sa r te a e m m o O g n fn o irtp Q ilA 3 H - 6 M : d ’i ' r i
» %«« * *v » ■n» » « * n r * 9 ¥* v »'.' * « « * « * . < « * » * • 1»h« «v * ? « * * * v » # * * %»*. » , «*.«»
SECTION 1D1
HR100T/HR110 MD AIR CONDITIONING
COMPRESSOR SERVICE OR
UNIT REPAIR R-134a
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR Component and Wiring Location
view in Section 9J before performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise
unneeded SIR system repairs.
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. Fasteners that are not reused, and those requiring thread
locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above
conditions are not followed, parts or system damage could result.
CONTENTS
General D e sc rip tio n ..........................................................ID 1—1 Compressor Clutch Coil and/or
Unit R e p a ir.........................................................................ID 1-3 Pulley R i m .............................................................. ID 1-6
Major Repair Procedures
Minor Repair Procedures
Compressor Shaft Seal .......................................... ID 1-7
C o m p re sso r.............................................................. ID 1-3 Compressor Pressure Relief Valve ...................... ID 1-9
Compressor Clutch Plate and Hub Compressor Control S w itch es.............................1D1-10
Assembly ................................................................ ID 1-3 Compressor Leak Testing ................................... ID 1—11
Clutch Rotor and/or B e a rin g ................................. ID 1-5 Compressor Special T o o ls ....................................1D1-13
GENERAL DESCRIPTION
Vehicles using the HR100T and HR110MD air The operations described in this manual are based on
conditioning compressor may have differences between bench overhaul with the compressor removed from the vehicle.
installations in their mounting brackets, drive systems, pulleys,
connector assemblies and system capacities, none of which However, some service operations depending on
will affect the following Overhaul Procedures. accessibility of the compressor, may be performed without
removing the compressor from the vehicle. These on-vehicle
When servicing the compressor, it is essential that steps operations are also identified in this manual.
be taken to prevent dirt or foreign material from getting on or
into the compressor parts and system during disassembly or All replacement compressors will be shipped from
reassembly. Clean tools and clean work area are very important Harrison with 240 ml (8 oz.) of PAG Lubricant. When a
for proper service. The compressor connection areas and the compressor is removed from the vehicle for servicing, drain the
exterior of the compressor should be cleaned off as much as PAG Lubricant from both the defective compressor and the
possible prior to any “on-vehicle” repairs or removal of the new replacement compressor. Measure the amount removed
compressor for workbench service. The parts must be kept from the defective compressor: if less than 1 oz. (30 ml) is
clean at all times and any parts to be reassembled should be drained from the old compressor, add 2 oz. (60 ml) to the new
cleaned with, naphtha, Stoddard solvent, kerosene or compressor. If more than 1 oz. (30 ml) is drained from the old
equivalent solvent and blown dry with dry air. When necessary compressor, add the same amount to the new compressor.
to use a cloth on any part, it should be of a non-lint producing NOTE: Replace only with GM approved PAG Lubricant P/N
type. 12345923.
1 P 1 -2 HR100T/HR110MD AIR CONDITIONING COMPRESSOR
2 — CLUTCH DRIVE
ASSEMBLY
3 — RETAINER RING,
ROTOR & BEARING
ASSEMBLY
4 — PULLEY ROTOR
5 — ROTOR BEARING
7 — RETAINER, SHAFT
SEAL
8 — SHAFT SEAL
10 — PUMP ASSEMBLY
11 — O-RING, PRESSURE
RELIEF VALVE
1 2 — HIGH PRESSURE
RELIEF VALVE
13 — SWITCH O-RING
14 — SYSTEM CONTROL
SWITCH (OPTIONAL)
15 — SWITCH, RETAINER
16 — SUCTION/DISCHARGE
PORT SEALING
WASHERS
1 7 — SPECIAL 134a
SUCTION PORT
1 8 — SPECIAL R134a
DISCHARGE PORT
OPTIONAL PARTS
1 9 — DUST COVER
UNIT REPAIR
MINOR REPAIR PROCEDURES When servicing the compressor, remove only the
necessary components that preliminary diagnosis indicates are
THE FOLLOWING OPERATIONS TO THE in need of service. Refer to Figure 1 for information relative to
COMPRESSOR CLUTCH PLATE AND HUB, ROTOR parts nomenclature and location.
AND BEARING, AND COIL & PULLEY RIM ARE
Removal and installation of external compressor
COVERED AS “MINOR” BECAUSE THEY MAY BE
components must be performed on a clean workbench. The
PERFORMED WITHOUT FIRST RECOVERING
work area, tools and parts must be kept clean at all times.
REFRIGERANT FROM THE SYSTEM OR REMOVING
THE COMPRESSOR FROM THE VEHICLE.
+ + Install or Connect
Install the shaft key into the hub key groove (Fig. 5).
Allow the key to project approximately 4.8mm (3/16")
out of the key way.
Align the shaft key with the shaft keyway and place the
Clutch Plate and Hub assembly onto the compressor
shaft.
1 -DRIVE PLATE
INSTALLER
J 9 4 0 1 -B
2 -DRIVE PLATE
INSTALLER
BEARING
3 -A IR GAP Fig. 8 Installing Rotor and Bearing Asm. (On-Vehicle)
(.015" - .020")
4 -CLUTCH On-Vehicle
PLATE AND
HUB ASM. A. Position the Rotor and Bearing assembly on the
front head.
B. With Rotor & Bearing Installer J 26271-A
(without driver handle) in position and Rotor and
Bearing assembly aligned with the Front Head as
Fig. 6 Installing Clutch Plate & Hub Asm. shown in Figure 8, drive the assembly part way
onto the head.
1 - J 25031
GUIDE
2 - J 25031 J 33020
ROTOR & PULLEY ROTOR
BEARING AND BEARING
PULLER
PULLER
3 -POLY
GROOVE
PULLEY
ROTOR
Fig. 9 Removing Clutch Rotor Asm. — Poly-Groove Drive Fig. 11 Pulley Rotor & Bearing Puller Removal
PULLEY ROTOR
FACE DOWN
J 33020
PULLEY ROTOR J 33020
AND BEARING J 29886 (LESS FORCING
PULLER PULLEY
DRIVER SCREW) INVERTED
ROTOR
HANDLE AND USED TO
SUPPORT HUB OF
MOTOR FOR
BEARING REMOVAL
PULLER TANGS
ENGAGED IN
J 9398-A MOTOR SLOTS.
BEARING
REMOVER
J 29886
CLUTCH ROTOR AND/OR BEARING DRIVER
HANDLE
Remove or Disconnect
J 9481-A
Remove the clutch plate and hub assembly as described
BEARING
previously. INSTALLER
Remove rotor and bearing assembly retaining ring, using J 21352-A
Snap Ring Pliers J 6083 (Fig. 7). SUPPORT
Install Pulley Rotor and Puller Guide J 2 5031 to the front BLOCK
head (Fig. 9), and install J 33020 Pulley Rotor and
Bearing Puller down into the inner circle of slots in the
rotor (Fig. 10). Turn the J 33020 puller clockwise in the
slots to engage the puller tangs with the segments
between the slots in the rotor.
Hold the J 33020 Puller in place and tighten the puller Fig. 13 Bearing Installation
screw against the Puller Guide to remove the pulley rotor
Remove the forcing screw from J 33020 Puller and with
and bearing assembly (Fig. 11). the puller tangs still engaged in the rotor slots, invert the
To prevent damage to the pulley rotor during bearing assembly onto a solid flat surface or blocks as shown in
removal, the rotor hub must be properly supported. Figure 12.
1D1 - 6 HR100T/HR110MD AIR CONDITIONING COMPRESSOR
6. Drive the bearing out of the rotor hub with Rotor Bearing installing the assembly onto the front head of the
Remover J 9398-A and J 29886 Universal Handle (Fig. compressor.
12). 6. Install rotor and bearing assembly retainer ring, using
It is not necessary to remove the staking in front of the Snap Ring Pliers J 6083 (Fig. 7).
bearing to remove the bearing, however, it will be 7. Reinstall clutch plate and hub assembly as described
necessary to file away the old stake metal (Fig. 15) for previously.
proper clearance for the new bearing to be installed into
the rotor bore or the bearing may be damaged.
1 - J 33019-1
BEARING
STAKING
GUIDE
2 -RUBBER
BAND
3 - J 33019-2
BEARING
STAKING
PIN
Install or Connect
On-Vehicle
Inspection
Seals should not be reused. Always use a new
specification service seal kit on rebuild. Care should be taken to
prevent damage to the lip of the one piece seal. Make sure that
the Seal Seat and Seal Lip are free of lint and dirt that could
damage the seal surface or prevent sealing.
On-Vehicle
Install or Connect
1. Dip the new seal O-ring in clean 525 viscosity refrigerant
oil and assemble onto O-Ring Installer
J 33011 (Fig. 19).
1 -S E A L 3 - J 9553-01 5 - J 33011
2 - J 23128-A 4 -O-RING 6 - J 34614
1 -LE A K TEST
ADAPTER
J-39893
2 -H IG H
PRESSURE
Fig. 20 Removing and Installing Shaft Seal Seat CUT-OFF
Retaining Ring SWITCH
1 -H IG H
PRESSURE
CUT-OFF
SWITCH
2 - “O” RING
3 -SWITCH
RETAINNING
RING
tJ
n°i
(Q
20
u 22
23
1. — J 4245 SNAP RING PLIERS (#23 INTERNAL) 14.— J 24092 PULLEY HUB ADAPTER SET
2. — J 5403 SNAP RING PLIERS (#21 INTERNAL) (USED WITH J 8433)
3. — J 6083 SNAP RING PLIERS (#24 INTERNAL) 15.— J 39500—GM R134a A/C REFRIGERANT RECOVERY,
RECYCLING AND RECHARGING
4. — J 29886 DRIVER HANDLE
SYSTEM (ACR4)
5. — J 8433 COMPRESSOR PULLEY PULLER
16.— J 25008-A COMPRESSOR HOLDING FIXTURE
6. — J 9398- A ROTOR BEARING REMOVER 17.— J 25031 ROTOR AND BEARING PULLER WITH
7. — J 33013-B HUB & DRIVE PLATE ASSEMBLY GUIDE
REMOVER 18.— J 25287 CLUTCH COIL PULLER
8. — J 9401 - B HUB & DRIVE PLATE ASSEMBLY 19.— J 26271 - A ROTOR AND BEARING INSTALLER
INSTALLER (WITHOUT HANDLE)
9. — J 9481 - A PULLEY BEARING AND PULLEY * 2 0 .— J 33019-1 BEARING STAKING TOOL
INSTALLER J 33019-2 BEARING STAKING PIN
10.— J 9553-01 O-RING REMOVER * 2 1 .— J 33020- A PULLEY PULLER
11. — J 39893 PRESSURE TEST CONNECTOR 22.— J 34614 SHAFT SEAL PROTECTOR
12.— J 21352-A COMPRESSOR SUPPORT BLOCK 23.— J 33011 SEAL SEAT O-RING INSTALLER
*1 3 .— J 23128—A SEAL REMOVER AND INSTALLER 24.— J 39400 LEAK DETECTOR
Indicates tools used only on the 6 pole clutch
BLANK
HP6/HR6-HE AIR CONDITIONING COMPRESSOR 1P2-1
SECTION 1D2
HD6/HR6-HE
AIR CONDITIONING COMPRESSOR
SERVICE OR UNIT REPAIR R-134a
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR Component and Wiring Location
view in Section 9J before performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise
unneeded SIR system repairs.
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. Fasteners that are not reused, and those requiring thread
locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above
conditions are not followed, parts or system damage could result.
CONTENTS
General D e sc rip tio n ..........................................................1D2-1 Major Compressor
Metric Thread Size Information ............................... 1D 2-3 Repair P rocedures........................................................1D2-8
Unit R e p a ir......................................................................... 1D2-3 Compressor Shaft Seal Replacement ..................1D 2-8
Minor Compressor Seal Leak Detection ...............................................1D 2-8
Repair P ro ced u res....................................................... 1D 2-3 Compressor Pressure Relief Valve .................... ID 2-10
Compressor Clutch Plate and Control S w itc h e s................................................... 1D2-11
Hub Assembly ....................................................... 1D 2-3 Compressor Leak Testing ................................... 1D2-11
Compressor Clutch Rotor and/or B e a rin g ........... 1D2-4 Bench-Check Procedures ............................... 1D2-11
Compressor Clutch Coil ........................................ 1D2-7 Special T o o ls ..........................................................1D2-12
GENERAL DESCRIPTION
The H D 6/H R6-H E Automotive Conditioning Service compressors are supplied with either the control
Compressor and Clutch Assembly is a lightweight, six cylinder switches assembled in the rear head or a plug may be found
axial design consisting of three double ended pistons and where a control switch is required. If the service compressor
weighs 5.8 kg (12.7 lbs.) requires control switches, the plug may be removed from the
appropriate rear head switch cavity of the replaced compressor
and assembled as prescribed in this manual.
1 — CLUTCH DRIVER
2 — ROTOR BEARING
RETAINER
3 — PULLEY BEARING
4 — PULLEY
5 — CLUTCH COIL
ASSEMBLY
7 — PUMP ASSEMBLY
8 — SWITCH O-RING
9 — SYSTEM CONTROL
SWITCH
1 0 — HIGH PRESSURE
RELIEF VALVE
12 — SUCTION/DISCHARGE
PORT SEALING
WASHERS
14 — SPECIAL 134a
DISCHARGE PORT
UNIT REPAIR
MINOR COMPRESSOR REPAIR center screw into the remover body to remove the clutch
plate and hub assembly (Fig. 3).
PROCEDURES
NOTICE: Do not drive or pound on the clutch hub or
THE FOLLOWING OPERATIONS TO THE shaft. Internal damage to compressor may result. The
COMPRESSOR CLUTCH PLATE AND HUB, ROTOR forcing tip on J 33013-B remover-installer center screw
AND BEARING, AND COIL ARE COVERED AS must be flat or the end of the shaft/axial plate assembly
“MINOR” BECAUSE THEY MAY BE PERFORMED will be damaged.
WITHOUT FIRST RECOVERING REFRIGERANT
FROM THE SYSTEM OR REMOVING THE 3. Remove the shaft key and retain for reassembly.
COMPRESSOR FROM THE VEHICLE.
The Compressor Shaft Seal assembly, control switches,
and Pressure Relief Valve may also be serviced WITHOUT
E l Install or Connect
1. Install the shaft key into the hub key groove (Fig. 4).
REMOVING THE compressor from the vehicle but these Allow the key to project approximately 3.2mm (1/8")
operations are covered later in this section as MAJOR REPAIR out of the keyway. The shaft key is curved slightly to
PROCEDURES because the system must be reclaimed, provide an interference fit in the hub key groove.
evacuated and recharged to complete service.
2. Be sure the frictional surface of the clutch plate and the
Illustrations used in describing these operations show the clutch rotor are clean before installing the clutch plate
compressor removed from the vehicle only to more clearly and hub assembly.
illustrate the various operations. 3. Align the shaft key with the shaft key way and place the
When servicing the compressor, remove only the parts clutch plate and the hub assembly onto the compressor
that preliminary diagnosis shows are in need o f service. Refer shaft.
to Figures 2 and 5 for information relative to part names and
location.
Removal and installation o f external compressor parts,
and disassembly and assembly of internal parts, must be
performed on a clean workbench. The work area, tools and
parts must be kept clean at all times.
a SHAFT KEYWAY
m SHAFT KEY
p H J 33013-B DRIVE ( T l AIR GAP (0.20"-
PLATE INSTALLER — 0.30 ) 0.50-0.76mm
Fig. 4 Shaft Key, Clutch Plate/Hub Installation
[T l DRIVE PLATE \T] CLUTCH PLATE
INSTALLER BEARING AND HUB ASM.
(T) J 6083
PLIERS
| T | PULLEY
ROTOR
[ T | RETAINING
RING
0
HUB OF ROTOR
[T]J 33023-A PULLEY 33020 PULLER FOR BEARING
J 29886 DRIVER
ROTOR AND ENGAGES IN INNER REMOVAL. PULLER
TANGS ENGAGED HANDLE
BEARING PULLER CIRCLE OF SLOTS
GUIDE IN ROTOR IN ROTOR SLOTS.
G 60 1 3 0 —1 D 2 - C - R 1
G 6 0 1 1 0 -1 D 2 -C -R 1
Fig. 7 Installing Pulley Rotor/Bearing Puller Guide Fig. 9 Pulley Rotor Bearing Removal
[» » | Install or Connect
0 J 8433-3 SCREW
[2] J 33023-A PULLER PILOT
[U J 33026-2 THROUGH BOLTS
1 -J 8433-3 SCREW 3—J 33024 CLUTCH
[ 4 ] PULLEY ROTOR COIL INSTALLER
IT I J 33017 PULLEY ROTOR AND BEAR- 2-C L U T C H COIL
L“J ING INSTALLER ASSEMBLY 4—J 8433 1 PULLER
CROSS BAR
[ | ] J 8433-1 CROSS BAR
____________5 2 0 0 1 9 -1 D 2 - R 1
Fig. 13 Installing Pulley Rotor and Bearing Assembly Fig. 15 Installing Clutch Coil Assembly
4 «■ Install or Connect
1. Place the clutch coil assembly on the front head with the
terminals positioned at the “marked” location.
2. Place the J 33024 clutch coil installer over the internal
CD J 8433-3 SCREW [ | ] J 8433-1 PULLER opening of the clutch coil housing and align installer
with the compressor front head.
[ T l MARK COIL TERMINAL CR°S S BAR
3. Center the J 8433-1 puller crossbar in the counter- sunk
LOCATION ON HEAD [ T ] J 33023-A
center hole of the J 33024 clutch coil installer. Install the
PULLER PILOT
CLUTCH COIL J 33026-2 through bolts and washers through the
ASSEMBLY crossbar slots and thread them into the holding fixture
0 J 33025 PULLER J 33026 to full fixture thickness (Fig. 15).
Fig. 16 Staking Clutch Coil to Front Head Fig. 17 Details of Stakes in Front Head for Clutch Coil
6. Install rotor and bearing assembly and the clutch plate 1-STEEL SHELL
and hub assembly as described previously. 2 -L IP SEAL
__________________________________________________________ 5 2 0 0 3 3 - 1 D1
Remove or Disconnect
+ «■ Install or Connect
Install or Connect
seal onto the shaft with a rotary motion until it stops.
Take care not to dislodge the O-ring. Be sure the seal 1. Clean valve seat area on rear head.
makes good contact with the O-ring. Disengage the
2. Lubricate O-ring of new pressure relief valve and O-ring
installer from the seal and remove the installer
assembly with new 525 viscosity refrigerant oil. Install
J 23128-A and the seal protector J 34614.
new valve and torque in place, 9.0 N«m (6.1 lbs.-ft.)
NOTICE: Handling and care of seal protector is
3. Evacuate and recharge the system.
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during installation. 4. Leak test system.
G 6 0 2 5 0 -1 D 2 -C -R 1
2. Lubricate the control switch housing with clean 14. Attach the compressor to the J 33026 holding fixture and
refrigerant oil and carefully insert switch into switch mount the compressor in a vise so that the compressor
cavity until switch bottoms in cavity. will be in a horizontal position and the shaft can be
turned with a wrench.
3. Using J 9533-1 snap ring pliers install switch retaining
ring with high point of curved sides adjacent to switch 15. Using a wrench, rotate the compressor crankshaft or
housing. Be sure retaining ring is properly seated in drive plate hub ten complete revolutions at a speed of
switch cavity retaining groove. Leak test according to approximately one-revolution per second. Turning the
bench test procedure. compressor at less than one-revolution per second can
result in a lower pump-up pressure and disqualify a good
pumping compressor.
COMPRESSOR LEAK TESTING 16. Observe the reading on high-pressure gage at the
(EXTERNAL AND INTERNAL) completion of the tenth revolution of the compressor.
The pressure reading for a good pumping compressor
Bench-Check Procedure should be 690 kPa (100 psi) or above. A pressure reading
of less than 620 kPa (90 psi) would indicate one or more
1. Install test plate J 39893 on rear head of compressor. suction and/or discharge valves leaking an internal leak,
2. Using J 39500-GM Refrigerant Recovery System, attach or an inoperative valve, and the refrigerant must be
center hose of manifold gage set on charging station to a recovered and the compressor disassembled and
refrigerant drum standing in an upright drum. checked for cause of leak. Repair as needed, reassemble
and repeat the pump-up test. Externally leak test.
3. Connect charging station high and low pressure lines to
corresponding fittings on test plate J 39893. Suction port 17. When the pressure pump-up test is completed, recover
(low-side) of compressor has large internal opening. the refrigerant from the high-side and remove the test
Discharge port (high-side) has smaller internal opening plate J 39893.
into compressor and deeper recess.
18. Tilt the compressor so that the compressor suction and
4. v^jjcn
Open iuw
low pressurec cumiui,
control, nigii
high pressure control and discharge ports are down. Drain the PAG lubricant from
refrieerant control on charging
refrigerant charein station to allow the compressor.
refrigerant vapor to flow into compressor.
19. Allow the compressor to drain for 10 minutes, then refill
Using a leak detector, check for leaks at pressure relief with the proper amount of PAG lubricant, per oil balance
valve, rear head switch location, compressor front and procedure in section IB of the service manual. The PAG
rear head seals, center cylinder seal, through bolt head lubricant may be poured into the suction port. If further
gaskets and compressor shaft seal. After checking, shut assembly or processing is required, a shipping plate or
off low pressure control and high-pressure control on test plate J 39893 should be installed to keep out air, dirt
charging station. and moisture until the compressor is installed.
1D 2-12 HD6/HR6-HE AIR CONDITIONING COMPRESSOR
GD E l 0
23
1 — J 5403 SNAP RING PLIERS 13 — J 33013 HUB & DRIVE PLATE REMOVER
& INSTALLER
2 — J 6083 SNAP RING PLIERS
14 — J39500-GM R134a A/C REFRIGERANT RECOVERY,
RECYCLING AND RECHARGING
3 — J 29886 DRIVER HANDLE
SYSTEM (ACR4)
4 — J 8433-1 PULLER BAR 15 — J 33017 PULLEY & BEARING ASSEMBLY
INSTALLER
5 — J 8 4 3 3 -3 FORCING SCREW
16 — J 33019 BEARING STAKING TOOL
6 — J 9 3 9 8 -A BEARING REMOVER
17 — J 33020 PULLEY PULLER
7 — J 9481 - A BEARING INSTALLER 18 — J 34614 SHAFT SEAL PROTECTOR
10 — J 23128—A SEAL SEAT REMOVER & 21 — J 33025 CLUTCH COIL PULLER LEGS
INSTALLER
22 — J 34992 COMPRESSOR HOLDING FIXTURE
11 — J 21352-A SUPPORT BLOCK 23 — J 39400 LEAK DETECTOR
SECTION 1D3
V5 AIR CONDITIONING
COMPRESSOR SERVICE OR
UNIT REPAIR R-134a
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR Component and Wiring Location
view in Section 9J before performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise
unneeded SIR system repairs.
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. Fasteners that are not reused, and those requiring thread
locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above
conditions are not followed, parts or system damage could result.
CONTENTS
General D escrip tio n ................................................... . . . 1D3-1 Major V5 Compressor Repair Procedures .........1D3-8
V5 Compressor - Theory of O p e ra tio n ............. . . . 1D3-1 Compressor Shaft Seal Replacement ..................1D3-9
Metric Thread Size Information ........................ . . . 1D3-2 Seal Leak Detection ................................. .........1D3-9
Unit R e p a ir.................................................................. . . . 1D3-2 Compressor Pressure Relief Valve ............. . . . . 1D3-10
Minor V5 Compressor Repair P rocedures......... 1D3-2
Compressor Control S w itc h es...................... 1D3-10
Compressor Clutch Plate and
Hub A ssem b ly ................................................. .. . 1D3-2 Compressor Control Valve A sse m b ly ......... . . . 1D3-11
Compressor Clutch Rotor and/or Bearing . . . .. . 1D3-5 Compressor Leak Testing (E xternal)..........., . . . 1D3-12
Compressor Clutch Coil ................................. . . . 1D3-7 Compressor - Special Tools ........................ . . . 1D3-13
GENERAL DESCRIPTION
Vehicles using the V5 compressor (Fig. 1) may have equivalent solvent and dried with dry air. Use only lint free
differences between installations in the mounting brackets, cloths to wipe parts.
drive systems, pulleys, connections, and system capacities. The operations described below are based on bench
Basic overhaul procedures are similar between compressors overhaul with the compressor removed from the car, except as
used on different vehicles. noted. They have been prepared in order of accessibility of the
components.
When a compressor is removed from the car for
servicing, the amount of PAG Lubricant remaining in the
compressor should be drained, measured and recorded. This
PAG Lubricant should then be discarded and an equal amount
of new PAG Lubricant added to the compressor.
NOTICE: Up to 120 ml (4 oz.) of PAG Lubricant can
collect in the crankcase. Therefore, it is important when
replacing a compressor that the PAG Lubricant in the old
compressor crankcase be drained thru the drain plug and
measured (discard after recording amount).
All replacement compressors will be shipped with 270 ml
(9 oz.) of PAG Lubricant in the crankcase. This lubricant must be
drained and retained. Then replace the lubricant in the same
amount as previously recorded from the old compressor. NOTE:
When servicing the compressor, keep dirt and foreign Replace only with GM approved PAG Lubricant P/N 12345923.
material from getting on or into the compressor parts and V5 COMPRESSOR - THEORY OF
system. Clean tools and a clean work area are important for
OPERATION
proper service. The compressor connections and the outside of
the compressor should be cleaned before any “on-vehicle” The V5 is a variable displacement compressor that can
repairs, or before removal of the compressor. The parts must be match the automotive air conditioning demand under all
kept clean at all t'm es and any parts to be reassembled should conditions without cycling. The basic compressor mechanism
be cleaned with naphtha, stoddard solvent, kerosene or is a variable angle wobble-plate with five axially oriented
1D 3-2 V5 AIR CONDITIONING COMPRESSOR
cylinders. The center of control of the compressor The compressor has a unique lubrication system. The
displacement is a bellows actuated control valve located in the crankcase-suction bleed is routed through the rotating
rear head of the compressor that senses compressor suction wobble-plate for lubrication of the wobble-plate bearing. The
pressure. The wobble-plate angle and compressor rotation acts as an oil separator, which removes some of the oil
displacement are controlled by the crankcase-suction pressure from the crankcase-suction bleed, rerouting it to the crankcase
differential. When the A/C capacity demand is high, the where it can lubricate the compressor mechanism.
suction pressure will be above the control point; the valve will METRIC THREAD SIZE INFORMATION
maintain a bleed from crankcase to suction: no
l. Compressor to mounting bracket bolts.
crankcase-suction pressure differential; and the compressor
Front M10 x 1.5 - 6H
will have maximum displacement. When the A/C capacity
Rear M 8xl.25-6H
demand is lower and the suction pressure reaches the control
MlOx 1.25-6H
point, the valve will bleed discharge gas into the crankcase and
close off a passage from the crankcase to the suction plenum. 2. Suction-discharge port screw.
MlOx 1 .5 -6 H
The angle of the wobble-plate is controlled by a force balance
on the five pistons. A slight elevation of the crankcase-suction 3. Compressor shaft.
pressure differential creates a total force on the pistons M9 x 1.25- 6 H
resulting in a movement about the w obble-plate pivot pin that 4. Internal hub-clutch drive assembly.
reduces the plate angle. M22 x 1.5- 6 H
UNIT REPAIR
MINOR PROCEDURES COMPRESSOR CLUTCH PLATE AND HUB
COMPRESSOR REPAIR ASSEMBLY
Illustrations used in the following operations show the Remove or Disconnect
compressor removed from the car for easier viewing. Refer to
Air Conditioning (Section IB) for compressor removal where Clamp the holding fixture J 34992 in a vise and attach
necessary. compressor to holding fixture with thumb screws
J 34992-1 (Fig. 4).
When servicing the compressor, remove only the parts
2. Keep the clutch hub and drive plate assembly from
that preliminary diagnosis show in need of service.
turning by using the clutch hub holding tool
Removal and installation of external compressor parts, J 33027-A. Remove the shaft nut using shaft nut socket
and disassembly and assembly of internal parts, must be J 33022 (Fig. 4).
performed on a clean workbench. The work area, tools and Thread the Clutch Plate and Hub Assembly Remover
parts must be kept clean at all times. J 33013-B into the hub. Hold the body of the remover
with a wrench and turn the center screw into the remover
body to remove the clutch plate and hub assembly
(Fig. 5).
4. Remove the shaft key and retain for reassembly.
Install or Connect
Install the shaft key into the hub key groove (Fig. 6).
Allow the key to project approximately 3.2 mm (1/8")
out of the keyway. The shaft key is curved slightly to
provide an interference fit in the hub key groove.
2. Be sure the frictional surface of the clutch plate and the
clutch rotor are clean before installing the clutch plate
and hub assembly.
Align the shaft key with the shaft key way and place the
clutch plate and the hub assembly onto the compressor
shaft.
NOTICE: Do not drive or pound on the clutch hub or
shaft. Internal damage to compressor may result.
2 - HIGH PRESSURE RELIEF VALVE
Remove the J 33013-B remover-installer center screw
3 - HIGH SIDE LOW PRESSURE SWITCH (If equipped) and reverse the body direction on the center screw as
shown in Figure 7.
4 - HIGH SIDE CUT-OFF SWITCH (If equipped) 5. Install the clutch plate and hub installer J 33013-B with
bearing as shown in Figure 7.
5 - COMPRESSOR CONTROL VALVE
The body of the J 33013-B installer should be backed off
Fig. 2 V5 Compressor Rear Head Details sufficiently to allow the center screw to be threaded onto
the end of the compressor shaft.
V5 AIR CONDITIONING COMPRESSOR 1D 3-3
2 — SHAFT NUT
4 — CLUTCH DRIVER
6 — PULLEY BEARING
RETAINER
7 — PULLEY BEARING
9 — PULLEY ROTOR
12 — SERVICE
COMPRESSOR
WITHOUT CLUTCH
13 — COMPRESSOR
CONTROL VALVE ASM.
14 — RETAINER RING
CONTROL VALVE
1 5 — HIGH PRESSURE
RELIEF VALVE
1 6 — RETAINER RING
SWITCH
17 — SYSTEM CONTROL
SWITCHES
18 — SUCTION PORT
SCREEN
19 — O-RING SWITCH
20 — SPECIAL 134A
SUCTION PORT
21 — SPECIAL 134A
DISCHARGE PORT
COMPRESSOR - REAR HEAD
AS VIEWED IN DIRECTION
OF ARROW “A”
Fig. 4 Removing Shaft Nut Fig. 6 Shaft Key, Clutch Plate/Hub Installation
Fig. 5 Clutch Plate and Hub Assembly Removal Fig. 7 Installing Clutch Plate & Hub Assembly
V5 AIR CONDITIONING COMPRESSOR 1D 3-5
1 - J 8083 PLIERS
2 - PULLEY ROTOR
3 - RETAINING RING
Fig. 8 Removing Pulley Rotor & Bearing Assembly Fig. 10 Removing Pulley Rotor and Bearing Assembly
Retaining Ring
6. Hold the center screw with a wrench. Tighten the hex
portion of the installer J 33013-B body to press the hub
onto the shaft. Tighten the body several turns, remove
the installer and check to see that the shaft key is still in
place in the keyway before installing the clutch plate
and hub assembly to its final position. The air gap
between frictional surfaces of the clutch plate and clutch
rotor should be 0.40-0.50m m (0.015-0.020").
• If the center screw is threaded fully onto the end of
the compressor shaft, or if the body of the installer
is held and the center screw is rotated, the key will
assume the position as shown in Figure 6 and will
break the clutch hub.
7. Remove installer J 33013-B, check for proper
positioning of the shaft key (even or slightly above the
clutch hub). Install the shaft nut. Hold the clutch plate
and hub assembly with clutch hub holding tool
J 33027-A and using shaft nut socket J 33022, tighten the
nut against the crankshaft shoulder to 16.5 N*m
(12 Ibs.ft.) torque, using a 17.5 N»m (12.5 lbs.ft.) torque
wrench.
8. Spin the pulley rotor by hand to see that the rotor is not
rubbing the clutch drive plate.
Fig. 11 Pulley Rotor Bearing Removal Fig. 12 Installing Pulley Rotor Bearing
6. Drive the bearing out of the rotor hub with rotor bearing 4. Using care to prevent personal injury, strike the staking
remover J 9398-A and J 29886 universal handle pin with a hammer until a metal stake, similar to the
(Fig. 11). original, is formed down to but not touching the
bearing.
NOTICE: It is not necessary to remove the staking in
front o f the bearing to remove the bearing, however, it The stake metal should not contact the outer face of the
will be necessary to file away the old stake metal fo r bearing to prevent the possibility of distorting the outer
proper clearance fo r the new bearing to be installed into race. Stake three (3) places 120° apart as shown in
the rotor bore or the bearing may be damaged. Figure 14.
5. With the compressor mounted to the J 34992 holding
fixture, position the rotor and bearing assembly on the
Install or Connect
front head (Fig. 15).
1. Place the pulley rotor on the J 21352-A support block to 6. Position the J 33017 pulley rotor and bearing installer
fully support the rotor hub during bearing installation and J 33023-A puller pilot directly over the inner race of
(Fig. 12). the bearing (Fig. 15).
V5 AIR CONDITIONING COMPRESSOR 1D 3-7
1 - J 33019
BEARING
STAKING
GUIDE
2 - RUBBER
BAND
3 - J 33019
BEARING
STAKING
PIN
STAKE THREE
(3) LOCATIONS 1 - J 8 4 3 3 -3 SCREW
120° A PART
2 - J 8433-1 PULLER CROSS BAR
3 - J 33025 PULLER LEG
4 - J 330 23 -A PULLER PILOT
5 - CLUTCH COIL ASSEMBLY
6 - MARK COIL TERMINAL LOCATION
ON HEAD
Install or Connect
1. Place the clutch coil assembly on the front head with the
terminals positioned at the “marked” location.
2. Place the J 33024 clutch coil installer over the internal
opening of the clutch coil housing and align installer
with the compressor front head.
3. Center the J 8433-1 puller crossbar in the countersunk
center hole of the J 33024 clutch coil installer. Install the
J 34992-2 through bolts and washers through the
crossbar slots and thread them, into the holding fixture
J 34992 to full fixture thickness (Fig. 17).
Clean
+ «■ Install or Connect
Install or Connect
Remove or Disconnect
6. Remove any excess oil resulting from installing the new □ Install or Connect
seal parts from the shaft and inside the compressor neck. Check switch cavity and O-ring groove in the rear head
7. Install the clutch plate and hub assembly as described in for dirt or foreign material and clean as necessary. Install
minor repair procedures. new O-ring coated with clean 525 viscosity refrigerant
oil into groove in switch cavity.
8. Reinstall the compressor, belt and tighten bracket.
9. Evacuate and charge the refrigerant system using 2. Lubricate the switch housing with clean 525 viscosity
refrigerant oil and carefully insert switch into switch
J 39500-GM.
cavity until switch “bottoms” in cavity.
3. Using J 5403 snap ring pliers, install switch retaining
COMPRESSOR PRESSURE RELIEF VALVE ring with high point of curved sides adjacent to the
switch housing. Be sure retaining ring is properly seated
+ + Remove or Disconnect in the switch cavity retainer ring groove.
4. Evacuate and recharge the system.
1. Recover refrigerant using J 39500-GM. 5. Leak test referring to “Compressor Leak Testing” in this
2. Remove old pressure relief valve (Fig. 2). section.
V5 AIR CONDITIONING COMPRESSOR 1D3-11
+ + Remove or Disconnect
+ 4» Install or Connect
5. Recover refrigerant.
6. Disconnect hoses from the test plate J 39893 and remove
test plate.
1 - LEAK TEST
Fig. 25 Lip Seal Installed on Seal Protector ADAPTER
J-39893
2 - HIGH
COMPRESSOR LEAK TESTING PRESSURE
(EXTERNAL) CUT-OFF
SWITCH
1. With sealing washers in place, install test plate J39893
on rear head of compressor and connect gage charging
lines and J 39500-GM .
2. Pressurize suction and high-side of compressor with
R134a refrigerant. With the compressor in horizontal
position, rotate the compressor shaft in normal direction
of rotation several turns by hand.
3. Using leak detector J 39400, check for leaks at pressure
relief valve, rear head switch location, compressor front
and rear head seals, through bolt head gaskets and Fig. 26 Compressor Leak Testing Fixture
compressor shaft seal.
V5 AIR CONDITIONING COMPRESSOR 1D 3-13
BLANK
- ■■--s■ ■
■
SD-7H15 AIR CONDITIONINQ COMPRESSOR 1D4-1
SECTION 1D4
CONTENTS
SUBJECT PAGE
General Description....................................................................................................................................................1D4-1
Inspection..................................................................................................................................................................1D4-1
Leak C heck........................................................................................................................................................... 1D4-1
Disassembly of the Clutch Assembly................................. ..............................................................................1D4-2
Assembly of the Clutch Assembly.....................................................................................................................1D4-3
Specifications.............................................................................................................................................................. 1D4-4
General Specifications........................................................................................................................................... 1D4-4
Fastener Tightening Specifications.....................................................................................................................1D4-4
Special Tools............................................................................................................................................................... 1D4-4
GENERAL DESCRIPTION
The Sanden SD-7H15 is a belt-driven seven cylinder The com pressor can be identified by a label attached
com pressor with an integral clutch. The clutch assem bly to the com pressor body giving the part number, model,
is the only part of this com pressor that is serviceable. and m anufacturer’s name. The date code is stam ped on
the front left mounting ear viewed as facing the clutch
(figure 1). It will be either a tw o-digit num ber or a num-
ber-letter com bination. The first num ber gives the year
of m anufacture. This is followed by one of the num bers
1 through 9, indicating the m onths January through
Septem ber. October, November, and D ecem ber are
indicated by an X, Y, or Z.
Although certain service operations can be perform ed
w ithout removing the com pressor from the vehicle, the
operations described here are based on bench repair
with the com pressor removed from the vehicle. They
have been prepared in order of accessibility to the com
ponents.
INSPECTION
LEAK CHECK
Before disassem bling any com pressor components,
check for leaks in the following areas:
DISASSEMBLY OF THE
CLUTCH ASSEMBLY
+-► Remove or Disconnect (Figures 1 through 7)
Tools Required:
J 6435 External Snap Ring Pliers
J 8433 Puller Set
J 37825 Puller Plate Assembly
J 37827 Puller Pilot
J 37828 Puller Fingers
J 37872 Spanner Wrench
• Insert the two pins of the J 37872 into any two
threaded holes of the clutch front plate. Hold the
clutch plate stationary (figure 2).
1. Hex nut using a 14 mm socket.
2. Clutch front plate using J 37825 (figure 3).
A. Align the puller center bolt to the compressor
shaft.
J 8433
r- !
Figure 6— Removing the Rotor Pulley (Cont.)
ASSEMBLY OF THE
CLUTCH ASSEMBLY
Install or Connect (Figures 2 and 8)
Tools Required:
J 6435 External Snap Ring Pliers
J 29640 Shaft Protector
J 29886 Driver Handle
J 37872 Spanner Wrench
J 38467 Bearing Remover and Installer
1. Clutch coil and snap ring retainer.
• The coil flange protrusions must match the hole
in the front housing to prevent coil movement
and to correctly place the lead wire.
2. Rotor pulley to the front housing hub and align.
A. Place J 38467 into the bearing cavity with the
outer edge on the rotor bearing outer race (fig
ure 8).
B. Place J 29886 into the ring.
C. Tap the end of J 29886 using a hammer. Guide 6. Shaft hex nut.
the rotor until it bottoms out against the com • Hold the plate with J 37872 (figure 2).
pressor front housing hub. Listen for a distinct
change of sound during the tapping process. ^ Tighten
3. External front housing snap ring with J 6435.
4. Front plate assembly. • Nut to 14 N-m (124 lbs. in.).
• Align the front plate keyway to the compressor • Check the air gap with a feeler gauge. It should
shaft key. be 0.49 to 0.79 mm (0.016 to 0.031 inch). If the
5. J 29640 to the compressor shaft. gap is not consistent all around, pry up slightly
• Tap the front plate to the shaft until the plate at points of minimum variation. Lightly tap down
bottoms to the clutch shims. at points of maximum variation. The gap is
determined by the shims. If necessary, add to
NOTICE: Refer to “Notice” on page 1D4-1. or remover shims from the shim stack.
1D4-4 SD-7H15 AIR CONDITIONING COMPRESSOR
SPECIFICATIONS
GENERAL SPECIFICATIONS
Type: Sanden SD-7H15.................................................................................................................................... 7 Cylinder Axial
Rotation........................................................................................................................................................................... Clockwise
Oil............................................................................................................................................................................ Sanden SP-20
Capacity...................................................................................................................................................................270 cc (9 oz.)
Clutch Hub Air Gap.......................................................................... ............................0.49 to 0.79 mm (0.016 to 0.031 in.)
SPECIAL TOOLS
1. J 8433 J 37828
2. J 29886
6.
J 38467
J 37825
7. J 37827
4. J 37872
1. PULLER SET
2. DRIVER HANDLE
3. PULLER PLATE ASSEMBLY
4. SPANNER WRENCH
5. PULLER FINGERS
6. BEARING REMOVER/INSTALLER
7. PULLER PILOT 2901r4920
STEERING 3-1
SECTION 3
STEERING
CONTENTS
SUBJECT PAGE
Power Steering Gear Unit Repair......................................................................................................................... 3B1A-1
Power Steering Pump Unit Repair........................................................................................................................3B1B-1
POWER STEERING GEAR UNIT REPAIR 3B1A-1
SECTION 3B1A
CONTENTS
Subsection A: 708 Power Steering Gear Subsection B: 710 Power Steering Gear
708 Power Steering Gear A ssem bly.................. .3B1A -2 710 Power Steering Gear A ssem bly.............. .... 3BIA-13
Steering Gear A djustm ents................................. . 3B1A-3 710 Power Steering Gear Service................... .... 3B1A-13
Worm Thrust Bearing Preload A djustm ent..... . 3B1A-3 Gear D isassem bly............................................. .... 3B1A-14
Pitman Shaft Over-Center Preload A djustm ent. 3BIA-4 Adjuster P lu g ..................................................... .... 3 B 1A-17
Steering Gear S ervice.......................................... . 3B1A-5 Valve and Stub S h a ft........................................ .... 3B1A-20
Pitman Shaft and Side Cover Replacem ent...... .3B1A-5 Pitman Shaft and Side C over........................... .... 3B1A-21
Housing End Plug Replacem ent........................ .3B1A -6 Primary Rack P isto n ......................................... .... 3B1A-22
Adjuster Plug Assembly Replacem ent .................. . 3B1A-7 Steering Gear C onnectors..................................... 3BIA-23
Valve Replacem ent.............................................. .3B1A-8 Pitman Shaft Bearing and
Rack Piston and Worm Shaft Replacem ent..... .3B IA -9 Seal R eplacem ent.............................................. .... 3BIA-23
Pitman Shaft Seals and Bearing Replacem ent... 3B1A-I1 Gear Reassem bly............................................... .... 3B1A-24
Check Valve R eplacem ent................................. 3B1A-12 Gear Service A djustm ents ......................................... . 3B1A-27
A-INDEX MARK
5 5 -PLUG, ADJUSTER B-SECOND INDEX MARK
Figure 4 Marking Housing Even with Adjuster Plug Figure 5 Remarking the Housing
POWER STEERING GEAR UNIT REPAIR 3B1A-5
7 -COVER, SIDE
4 0 -SHAFT, STUB
HI Tighten
+ «■ Install or Connect
Bolts (10) to 60 N*m (44 lb. ft.).
• Steering gear. Refer to “Power Steering Gear Re
Adjust placement” in Section 3B.
Pitm an shaft. R efer to “Pitm an Shaft
Over-Center Preload Adjustment” in this
section.
E3 Install or Connect
Steering gear. Refer to “Power Steering Gear
Replacement” in Section 3B.
A-SCREWDRIVER
5 3 -BEARING, NEEDLE
6 2 -RETAINER, BEARING
6mm (1/4")
A-VALVE ASSEMBLY
13-SHAFT, WORM
15-RACE
16-BEARING A-SHAFT PIN
17-RACE B-HOLE IN SPOOL
2 0 -HOUSING 4 0 -SHAFT, STUB
4 0 -SHAFT, STUB 43 - BODY, VALVE
Figure 15 Bearing, Worm and Valve Assembly Figure 16 Remove and Install Stub Shaft
POWER STEERING GEAR UNIT REPAIR 3B1A-9
A-PETROLEUM JELLY
2 3 -GUIDE, BALL A - MAKE SURE ANGLE OF THRUST RACES ARE AS
25 - BALLS SHOWN
Figure 21 Placing Balls in the Ball Return Guide Figure 22 Worm Shaft and Bearing
POWER STEERING GEAR UNIT REPAIR 3B1A-11
Notice: See “Notice” on page 3Bl A-1 of this section. PITMAN SHAFT SEALS AND BEARING
6. Ball guide clamp (22) and screws (2 1).
REPLACEMENT
Figures 1 and 2
^ Tighten This procedure covers the seal and bearing replacement for
steering gears. Seals may be replaced without removing
• Screws (21) to 58 N*m (43 lb. in.).
the power steering gear. Refer to “On Vehicle Service.”
• Insert J 21552 into bore of rack piston Tools Required:
(26) w hile tu rn in g w orm shaft (13) J 6278 Pitman Shaft Bearing Remover and
counterclockwise. The rack piston (26) will Installer
be forced onto J 21552 and will hold the rack J 6 2 19 Pitman Shaft Oil Seal Installer
piston balls (25) in place. J 4245 Internal Snap Ring Pliers
7. Races (15 and 17) and thrust bearing (16) to worm
Remove or Disconnect
shaft (13) (see Figure 22).
8. Worm shaft (13) to housing (20). • Pitman arm from steering gear. Refer to “Steering
9. Valve. Refer to “Valve Replacement” in this Linkage” in Section 3B3.
section.
10. Rack piston (26) to worm shaft (13) from J 21552,
using J 8947 to compress seals. Clean
• Hold J 21552 tightly against worm shaft and
turn stub shaft clockwise until rack piston • Exposed end of pitm an shaft (12) and
(26) is seated on worm shaft (13). housing (20).
• Use a wire brush toclean pitman shaft splines.
9 Important
• Make sure that all rack piston balls (25) are ❖ Disassemble
reinstalled in the rack piston. Improper rack
piston ball installation may result in personal S/T-Truck, M/G-Van
injury.
1. Retaining ring (35) using J 4245.
Rack piston plug (27).
Notice: Use care not to score the housing bore when
prying out seals and washers.
• R ack pisto n plug (27) to 150 N*m 2. Backup washer (31), and double lip seal (32) using
(111 lb. ft.). a screwdriver to pry them from the housing (20).
3. Backup washer (31) and single lip seal (30) using a
12. Housing end plug. Refer to “Housing End Plug screwdriver.
Replacement” in this section.
13. Pitman shaft and side cover. Refer to “Pitman Shaft b Inspect
and Side Cover Replacement” in this section.
H ousing (20) for burrs and rem ove if
necessary.
Adjust
Needle bearing (28).
• Steering gear. Refer to “Steering Gear Ad • Insert J 6278 through the hole in the top of the
justm ents” in Section 3B. housing (20) and drive out bearing (28).
Install or Connect
❖ Disassemble
• Steering gear. Refer to “Power Steering Gear
Replacement” in Section 3B. C/K-Truck, L-Van
3. Retaining ring (35) using J 4245. 5. Pitman shaft dust seal (64) (cavity facing out)
4. Backup washer (31) and pitman shaft seal (63) using using J 6219.
a screwdriver. • Cover entire cavity of dust seal (64) with white
petroleum grease.
Notice: Clean pitman shaft splines after packing seal
Z° Inspect cavity with grease.
• Housing (20) for burrs and rem ove if Notice: Pack the small cavity between pitman shaft seal
necessary. (63) and dust seal (64) with white petroleum grease before
reinstalling pitman shaft (12). Packing this area will help
4. Needle bearing (28). prevent early seal leaks by elim in atin g m oisture
• Insert J 6278 through the hole in the top of the accumulation, and rust on the pitman shaft.
housing (20) and drive out bearing (28).
6. Pitman shaft and side cover. Refer to “Pitman
Shaft and Side Cover Replacement” in this section.
Assemble • Coat lip of boot (65) with white petroleum grease.
S/T-Truck, M/G-Van
7. Boot (65) onto pitman shaft (12) until lip is seated
on chamfer of housing (20).
• Coat double lip seal (32) and washer (31) with white
petroleum grease. • Boot is moved into proper position by face of
pitman arm when pitman arm nut (37) is torqued to
1. Needle bearing (28) to housing (20) using J 6278. specification.
2. Single lip seal (30) (cavity facing in) using J 6219.
Install or Connect
Notice: Seal (30) must not bottom against needle • Pitman arm to steering gear. Refer to “Steering
bearing (28). Linkage” in Section 3B3.
3. Backup washer (31).
4. Double lip seal (32) (cavity facing in). CHECK VALVE REPLACEMENT
5. Backup washer (31).
6. Retaining ring (35) using J 4245.
Remove or Disconnect
Notice: Pack the small cavity between seals (30 and 32) • Steering gear from vehicle. Refer to “Power
with white petroleum grease before reinstalling pitman Steering Gear Replacement” in Section 3B.
shaft (12). Packing this area will help prevent early seal
leaks by eliminating moisture accumulation, and rust on
the pitman shaft. Disassemble
I*
7. Pitman shaft and side cover. Refer to “Pitman Shaft Notice: Use care not to damage threads of housing when
and Side Cover Replacement” in this section. removing check valve.
GEAR DISASSEMBLY
Figures 1 thru 9
Tools Required:
J 2 1552 Rack Piston Arbor
J 7624 Spanner Wrench
Disassem ble
*
1. R etaining ring (13), from both prim ary and
secondary cylinders (see Figure 1).
• Unseat retaining ring from housing (6). Use
a needle nose punch and rap with a hammer
(see Figure 3).
• Pry retaining ring out of housing groove
using a screwdriver.
A-SCREWDRIVER
2. Plug (12). Turn stub shaft (31) counterclockwise B-PUNCH
only until the plug is forced out of the primary 13-RING,RETAINING
cylinder.
Figure 3 Retaining Ring Removal
POWER STEERING GEAR UNIT REPAIR 3B1A-15
3. O-ring seal ( ll ) .
Im portant
• 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
9 Im portant only for replacement.
Aluminum square drive head (8), rap the plug Rotate the stub shaft (31) clockwise until the
sharply using a hammer and brass drift. Steel pitman shaft teeth (5) are free of the rack.
hexagon head (8) do not rap. Remove with a Turn the pitman shaft until the teeth are
1" socket. horizontal.
Insert tool J 21552 into the rack piston bore
4. Plug (8) from rack piston (50). Turn the plug with the pilot of the tool seated into the end of
counterclockwise. the worm (33).
5. Nut (1). Hold the tool against the worm and turn the
6. Bolts (2). stub shaft counterclockwise. The rack piston
7. Side cover (3). Turn adjuster screw on pitman Shaft (50) will be forced onto the tool.
(2) clockwise until the side cover (3) separates from Hold tool and pull the rack piston toward the
the pitman shaft (5) (Figure 5). handle until it touches the tool flange. This
• Turn stub shaft (31) clockwise until pitman prevents the end circuit balls from falling out.
shaft teeth (5) and rack pistons (50) and (7)
are disengaged (see Figure 6).
9 Im portant
A -CROSSOVER HOLE
B -VISE 5 -TEETH, PITMAN SHAFT
50 -PISTON, (RH) PRIMARY RACK 5 0 -PISTON, (RH) PRIMARY RACK
Figure 4 Crossover Hole Location Figure 6 Disengaging the Pitman Shaft Gear Assembly
3B1A-16 POWER STEERING GEAR UNIT REPAIR
Im portant
A-HAM MER
B-D R IFT
14 - NUT, ADJUSTER PLUG LOCK
1 9 -PLUG,ADJUSTER
31 - SHAFT, STUB
ADJUSTER PLUG 4. Retainer (25). Pry the retainer at the two raised areas
Figures 1,10 thru 22 (see Figure 12).
5. Spacer (24).
Tools Required: 6. Race (23).
J 4245 Internal Snap Ring Pliers, 7. Bearing (22).
J 8524-1 Bearing Seal Installer 8. Race (21).
J 8524-2 Bearing Remover 9. Seal (20).
J 7079-2 Driver 10. Needle bearing (18), if necessary. Use J 8524-2
Disassemble and J 7079-2 (see Figure 13).
17
19
Inspect
“T “
A ssem ble
J 7079-2
1. New needle bearing (18), if required. J 8524-1
• Place the new bearing over tools J 8524-1
and J 7079-2 with the m anufacturer’s
ID against the tool. Place a block of wood
under the adjuster plug (19) then press the
bearing into the adjuster plug until it bottoms
(see Figure 15).
• Lubricate seal (17) with power steering fluid.
2. Seal (17), use tool J 8524-1 (see Figure 16).
9 Im portant
Important
Valve assembly malfunction is uncommon,
except during seal replacement. Do not
service the valve unless indicated to do so.
♦ Disassemble
B
1. Seal (32) in the shaft cap end. I 1
2. Stub shaft (31) from the valve body (28) (Figure 20).
• Hold the assembly and lightly tap the stub
shaft against the bench until the shaft cap is A - DISENGAGE STUB SHAFT PIN
free from the valve body. FROM HOLE IN SPOOL VALVE
• Pull the shaft assem bly until the shaft
Figure 20 Stub Shaft Assembly Removal and Installation
cap clears the valve body by about 6 mm
(1/4 inch).
• Disengage the shaft pin from the valve spool.
• Remove the shaft assembly.
• Push the valve spool out of the opposite end
of the valve body (28) until the seal (29) is
exposed.
• Carefully pull the spool from the valve body
while rotating the valve.
3. Seal (29) from the valve spool.
Inspect
Seals (26) and rings (27) (see Figure 22).
Shaft pin for wear or cracks. If excessively
worn or broken, replace the complete valve
and shaft assembly.
Torsion bar and stub shaft (31) for leaking. If
there is leaking, replace the valve assembly
(see Figure 23).
Ground surface of the stub shaft (31). If a
crocus cloth cannot clean the nicks or burrs,
replace the valve assembly.
Outside diameter of the valve spool and
inside diameter of the valve body (28). If a
crocus cloth cannot clean the nicks or burrs,
replace the shaft and valve assembly.
The small notch in the skirt of the valve for
wear. If worn, replace the valve assembly.
Valve spool inside the valve body (28). The
valve spool, when lubricated with steering
fluid, must rotate freely without binding. If
binding occurs, replace the valve and shaft
assembly. 26 - SEAL, O-RING (VALVE BODY)
27 - RING, VALVE BODY
28 - BODY, VALVE
2 9 -SEAL, O-RING (SPOOL)
Important 30 - SPOOL, VALVE
31 - SHAFT, STUB
• Lubricate all wear surfaces with power 32 - SEAL, O-RING (STUB SHAFT)
steering fluid.
Figure 22 Valve Body and Stub Shaft Components
POWER STEERING GEAR UNIT REPAIR 3B1A-21
A ssem ble
9 Im portant
Z° Inspect
Assemble
l. New Seal (9) and ring (10) to rack piston (50).
• Lubricate new seal (9) and ring (10) with
power steering fluid.
Inspect Disassemble
*
Brass inverted flare connectors (51) for
looseness. Retaining ring (42). Use tool J 4245.
2. Dust seal (41). Pry with a screwdriver.
3. Washer (43).
Remove or Disconnect 4. Seal (44), using a screwdriver.
5. Bearing (45), if necessary, use tools J 24655 and
• Flare connectors (51), if necessary, and
J 8092 (see Figure 30).
discard. A modified No. 4 screw extractor
may be used to remove the connectors.
Install or Connect
1. New flare connectors (51).
• Drive connector seats in place using tool
J 6217 (see Figure 29).
3B1A-24 POWER STEERING GEAR UNIT REPAIR
GEAR REASSEMBLY
Figures 31 thru 39 J 24655
Tool Required:
J 6222-A Shaft Seal Protector
J 7624 Spanner Wrench
J 7754-01 Torque Wrench
Assemble
*
• Lubricate the worm (33), bearing (35), and
races (34) with power steering fluid.
1. Race (34), bearing (35), and race (34) over the end
of the worm (33). The race should be installed with
the angled surfaces parallel to each other (see Fig
A-PR E SS RAM
ure 32). 4 5 -BEARING ASM., NEEDLE (PITMAN SHAFT)
• Lubricate the valve body seals (26) and
the new shaft cap and seal (32) with power Figure 31 Pitman Shaft Bearing Installation
steering fluid.
• Align the narrow notch in the valve body
with the pin in the worm shaft cap (see Figure
33).
2. Valve (28) and worm (33) assembly into the gear
housing (6). Apply pressure only to the valve body
when installing (see Figure 34).
• The valve body is properly seated when the
oil return hole in the housing is entirely
uncovered.
• Place tool J 6222-A over the end of the stub
shaft.
Adjuster plug (19) assembly into the housing, until
it seats against the valve body (28).
Adjust
Bearing preload:
Use tool J 7624-01. Turn the adjuster plug
(19) clockwise until the plug and bearing
(22) are firmly bottomed— about 27 N»m
(29 lb. ft.).
Mark the housing in line with one of the holes
in the adjuster plug.
Measure back (counterclockwise) 13 mm
(1/2 in ch ) and re-m ark the hou sin g
(see Figure 35).
Rotate the adjuster counterclockwise until
hole in adjuster is in line with the second
mark (see Figure 35).
Tighten
7. Seal ( l l ) .
8. Housing end plug ( 12).
9. Retaining ring (13). The ring gap does not line up A-SECOND MARK
with the housing hole (see Figure 38). B-RULER
C-ORIGINAL MARK
D - ADJUSTER PLUG HOLE
J 7754-01
Figure 36 Checking the Bearing Preload Figure 39 Over Center Preload Adjustment
POWER STEERING GEAR UNIT REPAIR 3B1A-27
GEAR SERVICE ADJUSTMENTS 6. 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. Subtract this reading from reading
NOTICE: Repair the steering gear in a clean, dust-free taken in step 5. If the reading in step 5 is 0.23 N«m
location. Use clean tools and equipment. Dirt or grit will (2 lb. in.), then the gear is adjusted properly. Go to
damage the machined surfaces and result in leaking, or step 7. If less than 0.23 N*m (2 lb. in.), proceed with
damage to the steering gear assembly. the following adjustments.
• If the reading in step 5 is at least 0.23 N*m
Do not adjust with the steering gear installed in the vehicle. (2 lb. in.) and not more than 1.13 N*m
It is difficult to properly adjust the preload while taking (10 lb. in.), the gear is in proper adjustment.
torque readings through the steering column. Take the Proceed with adjustment in step 7.
time to make the adjustments properly, with the gear • If the reading in step 5 is less than 0.23 N«m
removed from the vehicle. (2 lb. in.) or more than 1.13 N*m (10 lb. in.),
z Adjust 7.
proceed with adjustment in steps 7 and 8.
With the gear on center, loosen adjuster plug lock
nut. Using spanner wrench J 7624, turn the adjuster
plug in (clockwise) until firmly bottomed in the
Z# Inspect
housing (approximately 20 lb. ft.).
Front end alignment. Mark the housing even with one of the holes
Drag link adjustment. in the adjuster plug.
Tire pressure. M easu re back in a c o u n te rclo c k w ise
direction 1/2 inch (approximately 20T) and
1. Place a container under the steering gear or pump to make a second mark on the housing.
catch fluid when disconnecting or connecting the Rotate adjuster plug counterclockwise until
power steering lines. Remove the gear from the hole in adjuster is in line with second mark.
vehicle. Tighten lock nut. Make sure adjuster plug
• Disconnect drag link from the pitman arm. does not move while lock nut is tightened.
• Disconnect steering coupling from the gear. Turn the stub shaft two turns right or left from
• Disconnect power steering lines at the gear. center. With the torque wrench installed on
• Remove four bolts that attach the gear to the the stub shaft near vertical, take the torque
gear support. reading. The torque reading should be
2. Place the gear in a vise. 0.56-1.13 N*m(5-10 lb. in.) while turning
the torque wrench in an arc 20° left or right of
vertical.
9 Important 8. With the gear on center, loosen the pitman shaft
adjuster lock nut. Make sure the adjusting screw is
Be sure to clamp the gear using soft jaws.
backed out counterclockwise all the way. Turn the
Clamp only on the mounting pads. Clamp adjuster screw clockwise 1/2 turn. This prevents the
ing the steering gear elsewhere can affect pitman shaft from bottoming out in the side cover.
your preload readings and cause gear dam
• Check preload by putting the torque wrench
age. vertical. Then move 90° left or right of
center. The torque reading should be the
3. Drain the oil from the gear by rotating the gear highest reading taken while turning the torque
through its complete travel several times. wrench back to center. Record the reading.
4. Center the steering gear by turning the stub shaft • Tighten the adjuster screw clockwise until
from the right wheel stop to the left wheel stop while the torque wrench reading is 0.68-1.13 N*m
counting the number of turns. Rotate the stub shaft
(6 -10 lb. in.) higher than the reading taken in
back half the of number turns to center position.
previous step.
5. Use torque wrench J 7754-01 and a deepwell
• Tighten the lock nut to 90 N*m (66 lb. ft.). Be
3/4" 12 pt. socket. Check the total preload torque by
sure the adjuster screw does not turn.
rotating through a 180° arc either side of center.
• Recheck the preload after tightening
Take the reading while turning back over the center
the locknut.
position. Record the highest reading.
9. Reinstall steering gear in vehicle.
3B1 A-28 POWER STEERING GEAR UNIT REPAIR
SPECIFICATIONS
FLUID SPECIFICATION
F A S T E N E R T IG H T E N IN G S P E C IF IC A T IO N S
A D JU S T M E N T T IG H T E N IN G S P E C IF IC A T IO N S
*Figure is in addition to worm shaft thrust bearing preload and valve and seal drag.
*Figure is in addition to worm shaft thrust bearing preload and valve and seal drag.
**Steering gear is considered used after it has been in service for 400 miles (650 km).
POWER STEERING GEAR UNIT REPAIR 3B1A-29
SPECIAL TOOLS
C
11. J 35509 12. J 6217 13. J 6222-A 14. J 7079-2
1. PITMAN SHAFT OIL SEAL INSTALLER 10. SEAL AND BEARING INSTALLER
2. INTERNAL SNAP RING PLIERS 11. SEAL AND BEARING REMOVER
3. SPANNER WRENCH 12. VALVE CONNECTOR SEAT INSTALLER
4. RACK PISTON TEFLON RING COMPRESSOR 13. SHAFT SEAL PROTECTOR
5. RACK PISTON ARBOR 14. DRIVER
6. ADJUSTER PLUG BEARING REMOVER AND INSTALLER 15. 0-2.8 N«M (0-25 LB. IN.) TORQUE WRENCH
7. PITMAN SHAFT BEARING REMOVER AND INSTALLER 16. HANDLE
8. SEPARATOR PLATE 17. BEARING SEAL INSTALLER
9. BEARING INSTALLER AND REMOVER 18. BEARING REMOVER
3B1A-30 POWER STEERING GEAR UNIT REPAIR
NOTES
POWER STEERING PUMP UNIT REPAIR 3B1B-1
SECTION 3B1B
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. Fasteners that are not reused and
those requiring thread locking compound will be called out. The correct torque value must be used when installing
fasteners that require it. If the above conditions are not followed, parts or system damage could result.
CONTENTS
Subsection A: P Series Power Steering Pump Subsection B: CB Series Power Steering Pump
P Series Power Steering Pump A ssem bly.......... .. 3B1B-2 CB Series Power Steering Pump Assembly .... .... 3B1B-5
P Series Power Steering Pump S e rv ic e .............. .. 3B1B-3 CB Series Power Steering Pump S erv ice........ .... 3B1B-6
Drive Shaft Seal R eplacem ent........................ .. 3B1B-3 Reservoir A ssem bly....................................... .... 3B1B-6
Pump Reservoir R eplacem ent........................ .. 3B1B-3 Control Valve A ssem b ly .............................. .... 3B1B-6
End Plate and Rotating Group R eplacem ent... 3B1B-4 Drive Shaft Seal
(without disassembly of p u m p )................... .... 3B1B-6
Hydraulic Pump A ssem bly........................... 3B1B-7
€ Disassemble
Clean
Protect drive shaft (12) with shim stock.
Seal (11) by cutting with a chisel.
Magnet (7).
€ Assemble
Lubricate seal (11) with power steering fluid.
i* Inspect
Welch plug in housing (8). Do not remove.
Seal (11) using J 22670. If plug is deformed or dislodged, replace
housing (8).
Install or Connect
Power steering pump. Refer to “Power Steering
Pump Replacement” in section 3B.
Remove or Disconnect
Power steering pump from vehicle. Refer to “Power
Steering Pump Replacement” in section 3B.
A-CHISEL
B-SHIM STOCK
11-SEAL, DRIVE SHAFT
12-SHAFT, DRIVE
Remove or Disconnect
Assemble
Pow er steering pum p from vehicle. R efer to
Lubricate O-ring seals (1,10,35 and 40) with power “Power Steering Pump Replacement” in section 3B.
steering fluid.
1. Flow control spring (6) and control valve assembly ❖ Disassemble
(2) to housing (8). See Figure 1 for proper orienta
tion. 1. Pump reservoir. Refer to “Pump Reservoir Replace
2 . O-ring seals (1, 10, and 40) to housing (8). ment” in this section.
3. Magnet (7) to housing (8). 2. Retaining ring (25).
4. Reservoir (37) to housing (8). 3. End plate (23) and spring (22).
5. O-ring seal (35) and fitting (33). Notice: Examine exposed portion of pump drive shaft. If it
Notice: See “Notice” on page 3B1B-1 of this section. is corroded, clean with crocus cloth before removing. This
will prevent damage to the shaft bushing that might require
6. Bolts (36). replacement of the entire housing.
4. Pressure plate (21) by using a rubber mallet to tap
lightly on the drive shaft (12).
5. Pump ring (20).
• Bolts (36) to 58 N*m (43 lb. ft.). 6 . Pump vanes (18).
• Fitting (33) to 75 N*m (55 lb. ft.). 7. Shaft, rotor and thrust plate assembly.
8. Shaft retaining ring (17).
Install or Connect 9. Pump rotor (16).
10. Thrust plate (15).
Power steering pump. Refer to “Power Steering 11 . Drive shaft (12).
Pump Replacement” in section 3B. 12. Dowel pins (13).
13. O-ring seals (3 and 5).
9 Important
Use new seals and drive shaft retaining ring
when assembling pump.
❖ Assemble
Lubricate O-ring seals (3 and 5) with power steering
fluid.
1. O-ring seals (3 and 5) to housing (8).
2. Dowel pins (13) to housing (8).
3. Thrust plate (15) and pump rotor (16) to drive shaft
(12) and secure with retaining ring (17).
4. Shaft, rotor and thrust plate assembly to housing (8).
5. Pump vanes (18) to pump rotor (16).
6. Pump ring (20) to housing (8) with identification
A-IDENTIFICATION ARROW arrows on top edge of ring (20) facing outward.
3-SEAL 7. Pressure plate (21).
5-SEAL 8. Spring (22) and end plate (23).
8-HOUSING
12-SHAFT, DRIVE 9. Retaining ring (25).
13-PINS, DOWEL 10 . Pump reservoir (37). Refer to “Pump Reservoir
15-PLATE, THRUST Replacement” in this section.
16-ROTOR, PUMP
17-RING, SHAFT RETAINING Install or Connect
18-VANES, PUMP
20-RING, PUMP Power steering pump. Refer to “Power Steering Pump
21-PLATE, PRESSURE
Replacement” in section 3B.
Figure 4 Rotating Group
POWER STEERING PUMP UNIT REPAIR 3B1B-5
RESERVOIR ASSEMBLY
Figure 1
44- Install or Connect
1. Flow control spring (12).
E Remove or Disconnect 2.
3.
Control valve assembly (13).
O-ring (15) on fitting (16).
1. Pump assembly from vehicle, if necessary for 4. Fitting ( 16) into hydraulic pump housing
access. assembly (10).
2. R etain in g clip s (3) and (5) from rese rv o ir
assembly (2) and housing (10).
3. Reservoir (2) from housing (10).
^ Tighten
4. O-ring seal (8) from reservoir (2) and discard.
• Fitting (16) to 75 N«m (55 lb. ft.).
COUNTERBORE
FACING DRIVE
SHAFT END OF
HOUSING
SPECIFICATIONS
FLUID SPECIFICATIONS
Lubricant........................................................................................................................................Power Steering Fluid 1050017
or Equivalent meeting GM Specification 9985010
CB Series Pump Capacity Complete S ystem ..........................................................................................0.75 liter (1-1/2 pints)
CB Pump O n ly ....................................................................................................................................................... 0.5 liter (1 pint)
SPECIAL TOOLS
FRONT AND REAR AXLES 4-1
SECTION 4
NOTES
ermrmo-
:• .
7 5/8-INCH RING GEAR 4B1-1
SECTION 4B1
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. Fasteners that are not reused, and those requiring thread locking compound will be called out.
The correct torque value must be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result
CONTENTS
SUBJECT PAGE
General Description.......................................................................... ....................................................................... 4B1- 1
Checking the Axle Before Disassembly.......................................................................................................... 4B1- 2
Disassembly of the Rear Axle.............................................. ............................................................................ 4B1- 2
Cleaning................ .................................................................................................................................................. 4B1- 4
Inspection............................................................................................................................................................... 4B1- 5
Axle Housing......................................................................................................................................................4B1- 5
Differential........................................................................................................................................................... 4B1- 5
Pinion and Ring Gear.......................................................................................................................................4B1- 6
Bearings .... ......................... ............................................................... ......... .......... .......................................... 4B1- 6
Shims................................................................................................................... ............................................... 4B1- 7
Assembly of the Rear Axle................................................................................... ............................................ 4B1- 7
Pinion Depth Adjustment................................................................................................................................ 4B1- 7
Differential Case Assembly................................................... ........................................................................4B1- 8
Side Bearing Preload Adjustment................................................................................................................ 4B1- 9
Pinion Installation............................................................................................................................................. 4B1-10
Backlash Adjustment........................................................................................................................................4B1-11
Gear Tooth Pattern Check...................................................................................................................................4B1-12
Gear Tooth Nomenclature............................................................................................................................... 4B1-12
Adjustments Affecting Tooth Contact............................................................................................................. 4B1-12
Final Assembly...................................................................................................................................................4B1-12
Specifications............................................................................................................................................................ 4B1-15
Fastener Tightening Specifications...................................................................................................................4B1-15
Spacer and Shim Specifications.......................................................................................................................4B1-15
Lubrication.............................................................................................................................................................. 4B1-15
Special Tools ............................................................................................................................................................. 4B1-16
GENERAL DESCRIPTION
The corporate 7 5/8-inch ring gear rear axle uses a the housing by "C" lock clips in the differential. The
conventional ring and pinion gear set to transmit the pinion gear is supported by tapered roller bearings The
driving force of the engine to the rear wheels. The gear pinion depth is set by a shim pack located between the
set transfers the driving force at a 90 degree angle from gear end of the pinion and the roller bearing pressed on
the propeller shaft to the axle shafts. the pinion. The pinion bearing preload is set by crush
This axle is semi-floating. The axle shafts are sup ing a collapsible spacer between the bearings in the
ported at the wheel end of the shaft by a roller bearing axle housing.
pressed into the housing. The shafts are retained into
4B1-2 7 5/8-INCH RING GEAR
The ring gear is secured to the differential case with DISASSEMBLY OF THE
10 left-hand threaded bolts.
The differential case is supported by two tapered roll REAR AXLE
er bearings. The differential and ring gear are located in
relationship to the pinion using selective shims and two +-► Remove or Disconnect (Figures 2 through 14)
spacers between the bearings and the axle housing. To
move the ring gear, shims are removed from one side Tools Required:
and an equal amount added to the other. These shims J 2619-01 Slide Hammer
J 22813-01 Axle Bearing Puller
are also used to preload the bearings pressed on the
J 8107-2 Differential Side Bearing Remover
differential case. Bearing caps hold the differential in
Plug
the axle housing.
J 22888 Side Bearing Remover
The differential allows the wheels to turn at different
J 8614-01 Pinion Flange Holder and Remover
rates of speed while the axle continues to transmit the J 25320 Rear Pinion Bearing Remover
driving force. This prevents tire scuffing during turns
• Place the axle in a suitable support.
and premature wear on internal axle parts.
1. Cover bolts and cover.
The axle is sealed by a pinion seal, a seal at each
axle shaft end, and a gasket between the cover and • Drain the axle lubricant.
axle housing. 2. Pinion shaft lock bolt (figure 3).
All corporate rear axles are identified by an alphanu 3. Pinion shaft.
meric broadcast code on the right axle tube as shown • Push the axle shaft in towards the center of the
in figure 1. differential case.
The axle housing cover does not have a drain plug. 4. The "C" lock from the end of the axle shaft.
5. Axle shaft from the axle housing (figure 4).
6. Oil seal using an oil seal removal tool.
CHECKING THE AXLE
• Be careful not to damage the housing.
BEFORE DISASSEMBLY 7. Bearing using J 2619-01 and J 22813-01 (figure 5).
• Make sure the tangs of the tool engage the
!? Inspect bearing outer race.
8. Differential pinion and side gears (figure 6).
1. Remove the axle cover and drain the lubricant. A. Roll the pinion gears out of the case with the
2. The ring gear backlash. Refer to "Backlash Adjust pinion thrust washers.
ments." This information can be used to determine B. Remove the side gears and the side gear thrust
the cause of the problem. It will also help when washers. Mark the gears and the differential
setting up the shim packs for locating and preload case left and right.
ing the differential case. 9. Bearing cap bolts.
3. The case for metal chips and shavings. Determine 10. Bearing caps.
where these chips and shavings came from, such • Mark the caps and the housing left and right.
as a broken gear or bearing cage.
4. Determine the cause of the axle problem before NOTICE: Be careful when prying the differen
disassembly if possible. tial case out of the axle housing so as not to
damage the cover gasket surface. The differ
ential case must be supported when it is
being removed to prevent the case from fall
ing and being damaged.
F4673
Figure 2—Rear Axle Components
4B1-4 7 5/8-INCH RING GEAR
15. Ring gear from the differential. 19. Collapsible spacer from the pinion (figure 13).
• Drive the ring gear off with a brass drift if nec 20. Outer seal and outer pinion bearing.
essary. 21. Inner bearing and shim from the pinion.
Figure 8—Removing Differential Side Bearings Figure 10— Removing/Installing the Pinion Nut.
J 8 6 1 4 -3
Figure 11— Removing the Pinion Flange Figure 13—Pinion Collapsible Spacer
Ring and pinion gears are matched sets and both are
• A new pinion flange must also be replaced when
replaced any time a replacement of either is necessary.
ring gear and pinion gear are replaced to maintain
proper system balance.
I? Inspect
BEARINGS
Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear. L1 Inspect
Pinion gear splines for wear.
Pinion flange splines for wear. Bearings for smooth rotation after oiling them.
The fit of the pinion gear splines on the pinion Bearing rollers for wear.
flange. Bearing cups for wear, cracks, brinelling, and scor
The sealing surface of the pinion flange for nicks, ing.
burrs, or rough tool marks that could cause dam
age to the seal’s inside diameter and result in an Important
oil leak.
All worn or broken parts and replace if necessary. When replacing worn or cracked bearings and
cups, make sure to replace them in sets.
7 5/8-INCH RING GEAR 4B1-7
Figure 16— Installing the Rear Pinion Bearing Cup Figure 18—Checking Pinion Depth
4B1-8 7 5/8-INCH RING GEAR
1. Clean all the gage parts. 1. Lubricate all parts with axle lubricant.
2. Lubricate the front and rear pinion bearings with 2. Thrust washers to the side gears.
axle lubricant (figures 17 and 18). 3. Side gears to the differential case.
3. Place the bearings into the pinion bearing cups. • Install the side gears on the same side as
4. Install J 21777-40, J 21777-42, J 21777-43, and removed.
J 23597-11 to the pinion bore (figure 17).
5. Hold the stud stationary at the flats of the stud. 4. Pinion gears to the differential without the thrust
washers.
Tighten A. Place one pinion gear on the side gear and
&
rotate the gear until the pinion is exactly oppo
• Stud nut to 2.2 N m (20 lbs. in.). site from the differential opening.
6. Rotate the gage plate and bearings several com B. Place the second pinion gear on the side gear
plete revolutions to seat the bearings. so the pinion gear holes line up.
7. Tighten the stud nut until a torque of 1.6 to 2.2 N-m C. Rotate the pinion gears into place, and verify
(15 to 25 lbs. in.) is obtained to keep the gage the pinion gears line up with the pinion shaft
plate in rotation. holes.
8 . Assemble J 21777-45, J 23597-11, and J 8001 to
5. Pinion thrust washers.
the differential bearing bores as shown in (figure
18). • Rotate the pinion gears toward the differential
• The bearing bores must be clean and burr free. opening enough to slide in the pinion thrust
9. Install the side bearing caps and tighten the bolts washers.
finger tight. 6. Pinion shaft.
10. Rotate the gage plate until the gaging areas are 7. Pinion shaft lock bolt.
parallel with the discs.
11 Position the gage shaft assembly in the carrier so • Check that the mating surfaces of the differen
that the dial indicator rod is centered on the gage tial case and the ring gear are clean and burr
area of the gage block. free.
12 Set the dial indicator at zero. Push the indicator 8. Ring gear to the differential case (figure 19).
down on the indicator shaft until the needle rotates
A. Install two threaded studs into the ring gear on
approximately 3/4 of a turn clockwise. Tighten the
opposite sides.
dial indicator in this position.
B. Place the ring gear on the case and align the
13. Rotate the gage shaft slowly back and forth until
studs with the holes in the case.
the dial indicator reads the greatest deflection. This
is when the indicator needle is centered between 9. Ring gear bolts.
moving to the left and to the right. • Tighten the ring gear bolts alternately and in
14. At the point of greatest deflection, set the dial indi stages, gradually pulling the ring gear onto the
cator to zero. Repeat the rocking action of the differential case.
gage shaft to verify the zero setting.
15. Rotate the gage shaft until the dial indicator rod Tighten
does not touch the gage block.
16. Record the actual number on the dial indicator and • The ring gear bolts in sequence to 120 N m (90
not the number that represents how far the needle lbs. ft.).
travels. This is the nominal pinion setting.
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.
17. All drive pinion gears are manufactured to a nomi
nal depth. There are no markings on the pinion for
depth. Dial indicator reading is the shim selection.
18. Remove bearing caps and depth gaging tools.
19. Install the correct pinion shim to the pinion
DIFFERENTIAL CASE ASSEMBLY
Tools Required:
J 25299 Differential Side Bearing Installer
J 8092 Driver Handle
J 8107-2 Differential Side Bearing Remover
Plug
7 5/8-INCH RING GEAR 4B1-9
J 5590
Figure 23—Measuring the Gage Plate Thickness Figure 25—Installing the Pinion Inner Bearing
7. Measure J 22779 in three places using a microme NOTICE: Proper pinion depth setting is a
ter. Average the readings (figure 23). two-step procedure.
8. Add the dimensions of the right side service spac 1. Setup dimension arrived at with the
er, service shim, and feeler gage. indicator to be considered a starting
9. For an initial backlash setting, move the ring gear point
away from the pinion by subtracting 0.25 mm 2. Gear tooth pattern check is necessary
(0.010 inch) from the ring gear side shim pack and to ”fine tune” the pinion depth and may
adding 0.25 mm (0.010 inch) to the shim pack on
indicate additional shim changes to the
pinion stem. Both procedures must be
the opposite side.
preformed to ensure proper axle perfor
10. To obtain the proper preload on the side bearings
mance and prevent system damage.
add 0.10 mm (0.004 inch) to the measurement of
each shim pack.
PINION INSTALLATION
11. Install the differential. Refer to "Backlash Adjust
ment." Install or Connect (Figures 2 and 25 through
33)
4.32 MM (0.170-INCH) SERVICE SPACER
Total Thickness Total Thickness of Service Tools Required:
of Both Prod. Shims To Be Used As A J 5590 Rear Pinion Bearing Cone Installer
Shims Removed Starting Point J 23911 Pinion Oil Seal Installer
1.52 mm (0.060- nch) J 8614-01 Pinion Flange Holder
10.57 mm (0.420- nch)
10.92 mm (0.430- nch) 1.78 mm (0.070- nch) • The bearing cups should have been installed in
11.18 mm (0.440- nch) 2.03 mm (0.080- nch) “Pinion Depth Adjustment.”
11.43 mm (0.450- nch) 2.29 mm (0.090- nch) 1 . The pinion inner bearing using J 5590 (figure 25).
11.68 mm (0.460- nch) 2.54 mm (0.100- nch) • Drive the bearing on until the cone seats on the
11.94 mm (0.470- nch) 2.79 mm (0.110- nch) pinion shims.
12.19 mm (0.480- nch) 3.05 mm (0.120- nch) 2. A new collapsible spacer.
12.45 mm (0.490- nch) 3.30 mm (0.130- nch)
• Lubricate the pinion bearings with axle lubri
12.70 mm (0.500- nch) 3.56 mm (0.140- nch)
cant.
12.95 mm (0.510- nch) 3.81 mm (0.150- nch)
13.21 mm (0.520- nch) 4.06 mm (0.160- nch)
3. Pinion to the axle housing.
4. Outer pinion bearing onto the pinion using J 5590.
13.46 mm (0.530- nch) 4.32 mm (0.170- nch)
13.97 mm (0.550- nch) 4.83 mm (0.190- nch) • Hold the pinion forward from inside the case
while driving the bearing onto the pinion.
T3228
5. Pinion oil seal using J 23911.
6. The pinion flange by tapping it with a soft-faced
Figure 24—Shim Thickness Chart hammer until a few threads show through the pin
ion flange.
7. The pinion washer and nut while holding the pinion
flange with J 8614-01.
7 5/8-INCH RING GEAR 4B1-11
l& l Tighten
£ Tighten
the “toe” end (2). The end of the tooth farthest away
from the center is the “heel” end (1). The toe end of the
tooth is smaller than the heel end (figure 29).
TEST
1. Wipe oil out of axle housing and carefully clean
each tooth of the ring gear.
2. Apply gear marking compound sparingly to all
ring gear teeth using a medium stiff brush.
3. Use the service brake to apply a load until a
torque of 54-68 N m (40-50 lbs. ft.) is required
to turn the pinion.
A test made without loading the gears will not
give a satisfactory pattern. Turn the companion
flange with a wrench so that the ring gear
rotates one full revolution. Then reverse the
rotation so that the ring gear rotates one revolu
tion in the opposite direction. Excessive turning
of the ring gear is not recommended.
4. Observe the pattern on the ring gear teeth and
Figure 28—installing the Differential Bearing compare with figure 30.
Preload Shim
ADJUSTMENTS AFFECTING
GEAR TOOTH CONTACT TOOTH CONTACT
PATTERN CHECK Two adjustments can be made that affect tooth con
tact pattern: backlash and drive pinion depth. The
Before final assembly of the differential, a gear tooth effects of bearing preloads are not readily apparent on
contact pattern check should be performed. hand-loaded tooth contact pattern tests. However, these
A gear tooth contact pattern check is NOT a substi adjustments should be within specifications before pro
tute for adjusting pinion depth and backlash as previ ceeding with backlash and drive pinion adjustments.
ously outlined. It is a method to verify the correct The position of the drive pinion is adjusted by
running position of the ring gear and the drive pinion. increasing or decreasing the distance between the pin
Gear sets which are not positioned properly may be ion head and the centerline of the ring gear. Decreasing
noisy, have a short life, or both. With a pattern check, the distance will move the pinion closer to the center-
the best contact between the ring gear and the drive line of the ring gear. Increasing the distance will move
pinion for low noise level and long life can be ensured. the pinion farther away from the centerline of the ring
GEAR TOOTH NOMENCLATURE gear.
Backlash is adjusted by means of the side bearing
The side of the ring gear tooth which curves outward, adjusting shims that move the case and ring gear
or is convex, is referred to as the “drive” side (4). The assembly closer to, or farther from, the drive pinion.
concave side is the “coast” side (3). The end of the (The adjusting shims are also used to set side bearing
tooth nearest the center of ring gear is referred to as preload).
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
Tools Required:
J 8092 Driver Handle
J 23765 Axle Shaft Bearing Installer
J 23771 Axle Shaft Seal Installer
J 23911 Pinion Oil Seal Installer
CONDITION: CONDITION:
• BACKLASH CORRECT. • BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT.
IS TOO FAR AWAY FROM RING GEAR.
TOE TOE
HEEL HEEL
CORRECTION: CORRECTION:
INCREASE THE PINION SHIM THICKNESS. NONE.
CONDITION:
• BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR
IS TOO CLOSE TO RING GEAR.
TOE
CORRECTION:
DECREASE THE PINION SHIM THICKNESS.
SERVICE HINTS:
PINION DEPTH SHIM LOCATIONS:
• BETWEEN THE INNER PINION BEARING CONE
AND THE HEAD OF THE PINION GEAR.
• BETWEEN THE INNER PINION BEARING CUP
AND THE REAR AXLE HOUSING.
3704r5056
Figure 31—Installing the Axle Bearing Figure 33— "C" Lock and Axle Shaft Seated in the
Side Gear
& Tighten
Tighten
SPECIFICATIONS
SPACER AND S H IM S P EC IFIC A TIO N S
7 5/8-INCH RING GEAR AXLE
Fastener N-m Lbs. Ft.
Axle Cover Bolts............................... 27 20
Bearing Cap Bolts............................. 75 55
Filler Plug........................................... 35 26
Pinion Shaft Lock Bolt..................... 34 25
Ring Gear Bolts................................. 120 90
LUBR IC ATIO N
Type 80W-90 GL-5
Liters Pints
Capacity. 1.85 4.0
T2508
4B1-16 7 5/8-INCH RING GEAR
SPECIAL TOOLS
1. J 7817 8. 22813-01
J 7818 9. 23911
4. J 8 6 1 4 -0 1
11 . 25320
12. 8092
5. J 22779
13. 8001
6. J 22888
3704S2402
8 1/2 AND 8 5/8-INCH RING GEAR 4B2-1
SECTION 4B2
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................. 4B2- 1
Checking the Axle Before Disassembly.......................................................................................................... 4B2- 2
Disassembly of the Rear Axle........................................................................................................................... 4B2- 2
Cleaning...................................................................................................................................................................4B2- 4
Inspection................................................................................................................................................................4B2- 5
Axle Housing..................................................................................................................................................... 4B2- 5
Differential........................................................................................................................................................... 4B2- 5
Pinion and Ring Gear....................................................................................................................................... 4B2- 5
Bearings.............................................................................................................................................................. 4B2- 6
Shims....................................................................................................................................................................4B2- 6
Assembly of the Rear Axle................................................................................................................................ 4B2- 6
Pinion Depth Adjustment................................................................................................................................ 4B2- 7
Pinion Installation..................................................................................................................................................4B2- 8
Differential Case Assembly............................................................................................................................ 4B2- 8
Side Bearing Pre-Load Adjustment............................................................................................................. . 4B2- 9
Backlash Adjustment........................................................................................................................................ 4B2-10
Gear Tooth Pattern Check...................................................................................................................................4B2-11
Gear Tooth Nomenclature................................................................................................................................ 4b2-11
Adjustments Affecting Tooth Contact.............................................................................................................. 4B2-13
Final Assembly...................................................................................................................................................4B2-13
Specifications............................................................................................................................................................ 4B2-14
Fastener Tightening Specifications...................................................................................................................4B2-14
Spacer and Shim Specifications........................................................................................................................ 4b2-14
Lubrication..................................... ......................................................................................................................... 4b2-14
Special Tools............................................................................................................................................................. 4B2-15
GENERAL DESCRIPTION
The corporate 8 1/2 and 8 5/8-inch ring gear axle The pinion depth is set by a shim pack located between
uses a conventional ring and pinion gear set to transmit the gear end of the pinion and roller bearing that is
the driving force of the engine to the rear wheels. This pressed onto the pinion. The pinion bearing preload is
gear set transfers the driving force at a 90 degree angle set by crushing a collapsible spacer between the bear
from the propeller shaft to the axle shafts. ings in the axle housing.
This axle is semi-floating. The axle shafts are sup The ring gear is bolted onto the differential case with
ported at the wheel end of the shaft by a roller bearing left-hand thread bolts.
pressed into the housing. The shafts are retained in the The differential case is supported in the axle housing
housing by retaining clips within the differential. The by two tapered roller bearings. The differential and ring
pinion gear is supported by two tapered roller bearings. gears are located in relationship to the pinion by using
4B2-2 8 1/2 AND 8 5/8-INCH RING GEAR
selective shims between the bearing and axle housing. 4. “C” clip (34) from the button end of the axle shaft
To move the ring gear, shims are removed from one (33).
side and an equal amount added to the other side.
• Push the axle shaft (33) in towards the center
These shims are also used to preload the bearings
of the differential case (24).
pressed into the differential case. Two bearing caps are
used to hold the differential in the axle housing. 5. Axle shaft (33) from the axle housing (1).
The differential allows the wheels to turn at different 6. Seal (28) using an oil seal removing tool.
rates of speed while the axle continues to transmit the
• Be careful not to damage the housing.
driving force. This prevents tire scuffing during turns
and premature wear on internal axle parts. 7. Bearing (27) using J 2619-01 and J 22813-01.
The axle is sealed at each axle shaft end, at the
• The tangs of the tool should engage the bear
differential pinion, and at the differential case cover.
ing outer race.
All corporate axles are identified by the alphabetic
broadcast code on the right axle tube near the carrier. 8. Pinion gear(21) and side gears (22).
The carrier cover does not have a drain plug.
• Roll the pinion gears out of the case with the
pinion thrust washers (20).
CHECKING THE AXLE • Remove the side gears and side gear thrust
BEFORE DISASSEMBLY washers (19). Mark the gears and the differen
tial case as left and right.
1? Inspect 9. Bearing cap bolts (18).
10. Bearing caps (10).
• Remove the axle cover from the axle and drain the
• Mark the caps and housing as left and right.
axle lubricant.
1. The ring gear backlash. Refer to “Backlash Adjust
ment.” This information can be used to determine NOTICE: Be careful when prying the differen
the cause of the axle problem. It will also help
tial case out of the axle housing so as not to
damage the cover gasket surface. The differ
when setting up the shim packs for locating and
ential case must be supported when it is
preloading the differential case.
being removed to prevent the case from fall
2. The case for metal chips and shavings. Determine ing and damaging the case.
where these chips and shavings came from, such
as a broken gear or bearing cage.
11. Differential case (24).
• Determine the cause of the axle problem before
disassembly if possible. • Pry the case from the axle housing at the differ
ential “window” (figure 3).
DISASSEMBLY OF THE 12. Bearing outer races and shims.
REAR AXLE • Mark the races and shims as left and right, and
place them with the bearing caps.
Remove or Disconnect (Figure 1)
13. Differential side bearings (8) using J 8107-4 and
J 22888-20 (figure 4).
Tools Required:
J 2619-01 Slide Hammer • The jaws of J 22888-20 must pull from beneath
J 22813-01 Axle Bearing Remover the bearing cone and not the cage. Use the
J 8107-4 Differential Side Bearing Remover slots provided for the puller.
Plug 14. Ring gear bolts (23).
J 22888-20 Side Bearing Remover
J 8614-01 Pinion Flange Remover • Ring gear bolts use left-handed threads.
J 8612-B Rear Pinion Bearing Cone Remover
• Place the axle in an approved support. NOTICE: Do not pry the ring gear from the
case. This will damage the ring gear and dif
1. Differential cover bolts (14) and cover (12). ferential case.
• Drain the gear lubricant.
• Refer to “Checking the Axle Before Disassem 15. Ring gear (7) from the differential case.
bly.”
• Drive the ring gear off with a brass drift if nec
2. Pinion shaft lock bolt (15) (figure 2). essary.
3. Pinion shaft (17).
8 1/2 AND 8 5/8-INCH RING GEAR 4B2-3
21
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. WASHER, LOCK
10. CAP, DIFF BEARING 27. BEARING, REAR WHEEL
11. GASKET CARRIER COVER 28. SEAL, REAR AXLE SHF (OIL)
12. COVER, DIFF CARRIER 29. PLATE, BRAKE BACKING
13. CLIP, BRAKE CROSSOVER PIPE 30. BOLT, HEX
14. BOLT, HEX SERRATED COVER 31. DRUM, REAR BRAKE
15. BOLT, DIFF P/GR SHF LK 32. BOLT, REAR
17. SHAFT, DIFF PINION 33. SHAFT, AXLE
18. BOLT, HEX 34. LOCK, REAR AXLE SHF (OIL)
19. WASHER, DIFF SIDE GEAR 35. NUT, PINION FLANGE
20. WASHER, DIFF PINION 36. WASHER, PINION FLANGE
21. GEAR, DIFF PINION 37. FLANGE ASM, PINION
22. GEAR, DIFF SIDE 38. SEAL ASM, PINION
23. BOLT, HYPOOID DRIVE GEAR 39. BEARING, OUTER PINION
V3952
I* Inspect 21. Inner bearing (5) and shim (6) from the pinion.
A. Press the bearing off the pinion using J 8612-B
• Drive pinion bearing preload and record for ref (figure 9).
erence upon reassembly (figure 5). B. Remove the shim.
• For looseness of pinion assembly by moving it 22. Bearing cups (5 and 39) from the axle housing
back and forth. (This indicates excessive bear using a hammer and punch.
ing wear). • Work the cups out of the housing evenly, mov
ing the punch back and forth between one side
16. Pinion flange nut (35) and washer (36) using of the cup and the other. Use the slots provided
J 8614-01 to hold the pinion flange (figure 6). for this purpose.
17. Pinion flange using J 8614-01 (figure 7).
18. Pinion (7) from the axle housing. CLEANING
A. Thread the pinion nut halfway onto the pinion. Do not steam clean drive parts having ground and
B. Replace the differential cover (12) with two bolts polished surfaces such as gears, bearings, and shafts.
(14) to keep the pinion from falling to the floor. All parts should be disassembled before cleaning.
C. Drive the pinion out of the housing with a ham These parts should be cleaned in a suitable solvent.
Parts should be thoroughly dried immediately after
mer and a soft drift (figure 8).
cleaning. Use soft, clean, lintless rags. Parts may be
19. Collapsible spacer (4) from the pinion. dried with compressed air. Do not allow the bearings to
20. Outer oinion seal (38) and bearing (39). spin while drying them with compressed air.
8 1/2 AND 8 5/8-INCH RING GEAR 4B2-5
Figure 6—Removing the Drive Pinion Nut Figure 8—Removing the Drive Pinion
J 22912 - 0 1
Figure 7—Removing the Pinion Flange Figure 9—Removing the Pinion Rear Bearing
DIFFERENTIAL
INSPECTION
It is critical to carefully and thoroughly inspect all I? Inspect
drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or • Pinion gear shaft for unusual wear.
stress and subsequent replacement of worn parts will • Pinion gear and side gear teeth for wear, cracks,
eliminate costly drive component repair after reassem scoring, and spalling.
bly. • Thrust washers for wear.
AXLE HOUSING • The fit of the side gears in the differential case.
• The fit of the side gears on the axle shafts.
L* Inspect • Differential case for cracks and scoring.
• Replace all worn parts.
The carrier bore for nicks or burrs that would pre PINION AND RING GEAR
vent the outer diameter of the pinion seal from
sealing. Remove any burrs that are found.
The bearing cup bores for nicks or burrs. Remove
I
?Inspect
any burrs that are found. Pinion and ring gear teeth for cracking, chipping,
The housing for cracks. Replace the housing if any scoring, or excessive wear.
cracks are found. Pinion gear splines for wear.
The housing for foreign material such as metal Pinion flange splines for wear.
chips, dirt, or rust. Refer to “Cleaning.” The fit of the pinion gear on the pinion flange.
4B2-6 8 1/2 AND 8 5/8-INCH RING GEAR
Important
BEARINGS
L1 Inspect
Figure 10—Installing the Front Pinion Bearing Cup
• Bearings visually and by feel.
• The bearings should feel smooth when oiled and
rotated while applying as much hand pressure as
possible.
• The large end of the bearing rollers for wear. This
is where tapered roller bearing wear is most evi
J 7818
dent.
• Bearing cups for wear, cracks, brinelling, and scor
ing.
• Bearings and cups are replaced only as sets.
• If the axle was operated for an extended period
of time with very loose bearings, the ring gear
and drive pinion will also require replacement.
• Low mileage bearings may have very small
scratches and pits on the rollers and bearing
cups from the initial preload. Do not replace a
bearing for this reason.
• Bearing caps for cracks or chips.
SHIMS
fi Inspect
Tools Required:
J 8608 Rear Pinion Bearing Cup Installer
J 8611-01 Front Pinion Bearing Cup Installer
J 8092 Driver Handle
1. Front pinion bearing cup (39) using J 8611-01 and
J 8092 (figure 10) .
2. Rear pinion bearing cup (5) using J 8608 and Figure 12—Gage Plate Tools
J 8092 (figure 11).
8 1/2 AND 8 5/8-INCH RING GEAR 4B2-7
Tighten
Tools Required:
J 8107-4 Differential Side Bearing Remover
Plug
J 8092 Driver Handle
J 22761 Differential Side Bearing Installer
• Lubricate all parts with axle lubricant.
I.S id e gear thrust washers (19) to the side gears
Figure 15—Installing the Pinion Oil Seal (22 ).
Firtfjre 16— Installing the Pinion Flange Figure 17—Checking Pinion Bearing Preload
8 1/2 AND 8 5/8-INCH RING GEAR 4B2-9
St Tighten
3. Push the ring gear towards the pinion. • The point just before additional drag begins is
• Engage the ring gear with the pinion tightly, to a the correct feeler gauge thickness. This is the
backlash of 0.000 inch (No noticeable loose zero setting without preload.
ness).
8. Remove the strap, J 22779, the service spacer,
4. Insert J 22779 between the axle housing and left
service shim, feeler gauge, and differential case
bearing cup (figure 21).
from the axle housing.
5. Move the tool back and forth in the bore while
9. Measure J 22779 in three places using a microme
turning the adjusting nut clockwise until a notice
ter. Average the readings (figure 23).
able drag is produced (figure 22).
10. Add the dimensions of the right side service spac
A. Tighten the lock bolt on the side of the tool.
er, service shim, and feeler gauge.
B. Leave the tool in place.
11. For an initial backlash setting, move the ring gear
6. Install a service spacer (9) and service shim (9) away from the pinion by subtracting 0.010 inch
between the right bearing cup and axle housing.
from the ring gear side shim pack and adding
7. Determine bearing preload by inserting progres
0.010 inch to the shim pack on the opposite side.
sively larger feeler gauge sizes between the carrier
12. To obtain the proper preload on the side bearings
and service shim.
add 0.10 mm (0.004 inch) to the measurement of
• Push the feeler gauge downward so it contacts
each shim pack.
the shim at the top and bottom and then con
13. Install the differential. Refer to “Backlash Adjust
tacts the axle housing.
ment.”
BACKLASH ADJUSTMENT
1. Install the differential case, bearing cups, spacers,
and shims as determined from the “Side Bearing
Preload Adjustment.” (figure 24).
• Tap the final shim into position, using a soft
faced hammer.
2. Rotate the case several times to seat the bearings.
3. Install a dial indicator to the case using a magnetic
base.
4. Place the indicator stem at the heel end of a tooth.
• Set the dial indicator so the stem is in line with
the gear rotation and perpendicular to the tooth
angle (figure 25).
5. Install the differential caps and bolts.
Tighten
GEAR TOOTH
PATTERN CHECK
Before final assembly of the differential, a gear tooth
contact pattern check should be performed.
A gear tooth contact pattern check is NOT a substi
tute for adjusting pinion depth and backlash as previ
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.
TEST
1. Wipe oil out of axle housing and carefully clean
each tooth of the ring gear.
2. Apply gear marking compound sparingly to all
ring gear teeth using a medium stiff brush.
3. Use the service brake to apply a load until a
torque of 54-68 N-m (40-50 lbs. ft.) is required
to turn the pinion.
A test made without loading the gears will not
give a satisfactory pattern. Turn the companion
flange with a wrench so that the ring gear
rotates one full revolution. Then reverse the
rotation so that the ring gear rotates one revolu
tion in the opposite direction. Excessive turning
of the ring gear is not recommended.
4. Observe the pattern on the ring gear teeth and
6. Check and record the backlash at three or four compare with figures 27.
points around the ring gear.
• The pinion must be held stationary when check
ing backlash.
• The backlash should be the same at each point
within 0.05 mm (0.002 inch). If the backlash
varies more than 0.05 mm (0.002 inch), check
for burrs, a distorted case flange, uneven bolt
ing conditions, or foreign matter between the
case and ring gear.
7. Backlash at the minimum lash point measured
should be between 0.13 to 0.23 mm (0.005 to
0.009 inch) for all new gear sets.
8. If the backlash is not within specifications, move
the ring gear in or out from the pinion by increasing
the thickness of one shim, and decreasing the
thickness of the other shim the same amount. This
will maintain the correct axle side bearing preload.
• Moving 0.003 inch worth of shim from one side
of the differential to the other will change the
backlash adjustment by 0.002 inch.
9. Recheck the backlash and correct as necessary.
4B2-12 8 1/2 AND 8 5/8-INCH RING GEAR
CONDITION: CONDITION:
• BACKLASH CORRECT. • BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT
IS TOO FAR AWAY FROM RING GEAR.
TOE
HEEL A HEEL
CORRECTION: CORRECTION:
INCREASE THE PINION SHIM THICKNESS. NONE.
CONDITION:
• BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR
IS TOO CLOSE TO RING GEAR.
TOE
CORRECTION:
DECREASE THE PINION SHIM THICKNESS.
SERVICE HINTS:
PINION DEPTH SHIM LOCATIONS:
• BETWEEN THE INNER PINION BEARING CONE
AND THE HEAD OF THE PINION GEAR.
• BETWEEN HTE INNER PINION BEARING CUP
AND THE REAR AXLE HOUSING.
3704r4220
ADJUSTMENTS AFFECTING
TOOTH CONTACT
Two adjustments can be made that affect tooth con
tact pattern: backlash and drive pinion depth. The
effects of bearing preloads are not readily apparent on
hand-loaded tooth contact pattern tests. However, these
adjustments should be within specifications before pro
ceeding with backlash and drive pinion adjustments.
The position of the drive pinion is adjusted by increas
ing or decreasing the distance between the pinion head
and the centerline of the ring gear. Decreasing the dis
tance will move the pinion closer to the centerline of the
ring gear. Increasing the distance will move the pinion
farther away from the centerline of the ring gear.
Backlash is adjusted by means of the side bearing
adjusting shims that move the case and ring gear assem
bly closer to, or farther from, the drive pinion. (The adjust
ing 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.
If the thickness of the left shim is increased (along
with decreasing the right shim thickness), backlash will
decrease.
FINAL ASSEMBLY
Tools Required:
J 8092 Driver Handle
J 23765 Axle Shaft Bearing Installer
J 23771 Axle Shaft Seal Installer
J 23911 Pinion Oil Seal Installer
Install or Connect (Figures 1, 28 through 30)
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener N-m Lbs. Ft.
Axle Cover Bolts... 27 20
Bearing Cap Bolts. 80 60
Filler Plug.............. 35 26
Ring Gear Bolts.... 120 90
SPACER AND SHIM SPECIFICATIONS
Spacer and Shim Sizes Size
Differential Side Bearing Spacer... 0.170-inch
SPECIAL TOOLS
1. J 8611-01 8. J 8608
2. fO i i | J8612-B 9. J 22888
J 8001 11 J 22761
7. J 8107-4
1. Front Pinion Bearing Cup Installer 11. Differential Side Bearing Installer
2. Rear Pinion Bearing Cone Remover 12. Side Bearing Backlash Gauge
3. Driver Handle 13. Rear Pinion Bearing Cone Installer
4. Dial Indicator Set Not Shown:
5. Rear Pinion Bearing Cone Installer J 21777-1 Arbor
6. Pinion Flange Remover J 21777-29 Gauge Plate
7. Differential Side Bearing Remover Plug J 21777-35 Rear Pilot Washer
8. Rear Pinion Bearing Remover Plug J 21777-42 Front Pilot Washer
9. Side Bearing Remover J 21777-43 Stud Assembly— Bolt
10. Pinion Oil Seal Installer J 21777-45 Side Bearing Disc
F4660
4B2-16 8 1/2 AND 8 GEAR
■'iMi
NOTES
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.
. ft
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• •* * r/A ^ ■ ci V
• • -0 [^ <' ^ C? — \r5 ’ t
•" * ■ ? ** ' ' . ' ‘ ' i f ? " " p.
dttsf?n 1?S98 irO -? ' *“
9 1/2-INCH RING GEAR 4B3-1
SECTION 4B3
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................4B3- 1
Checking the Axle Before Disassembly.......................................................................................................... 4B3- 2
Disassembly of the Rear Axle........................................................................................................................... 4B3- 2
Cleaning...................................................................................................................................................................4B3- 5
Inspection................................................................................................................................................................4B3- 5
Axle Housing......................................................................................................................................................4B3- 5
Differential........................................................................................................................................................... 4B3- 5
Pinion and Ring Gear....................................................................................................................................... 4B3- 5
Bearings.............................................................................................................................................................. 4B3- 5
Shims....................................................................................................................................................................4B3- 6
Assembly of the Rear Axle................................................................................................................................ 4B3- 6
Pinion Depth Adjustment.................................................................................................................................4B3- 6
Pinion Installation............................................................................................................................................. 4B3- 7
Differential Case Assembly............................................................................................................................ 4B3- 8
Side Bearing Preload Adjustment.................................................................................................................4B3- 9
Backlash Adjustment........................................................................................................................................ 4B3-10
Gear Tooth Pattern Check...................................................................................................................................4B3-10
Gear Tooth Nomenclature............................................................................................................................... 4B3-10
Adjustments Affecting Tooth Contact.......................................................................................................... 4B3-11
Final Assembly...................................................................................................................................................4B3-11
Specifications............................................................................................................................................................ 4B3-14
Fastener Tightening Specifications...................................................................................................................4B3-14
Spacer and Shim Specifications....................................................................................................................... 4B3-14
Lubrication.............................................................................................................................................................. 4B3-14
Special Tools............................................................................................................................................................. 4B3-15
GENERAL DESCRIPTION
The corporate 9 1/2-inch ring gear rear axle uses a The ring gear bolts to the differential case with
conventional ring and pinion gear set to transmit the left-hand thread bolts.
driving force of the engine to the rear wheels. The gear The differential case is supported by two tapered roll
set transfers this driving force at a 90-degree angle er bearings. The differential and ring gears are located
from the propeller shaft to the axle shafts. in relationship to the pinion using selective shims
This axle is semi-floating. The axle shafts are sup between the bearing and axle housing. To move the
ported at the wheel end of the shaft by roller bearings ring gear, remove shims from one side and add an
pressed into the housing. The shafts are retained into
equal amount added to the other side. The differential
the housing by retaining clips in the differential. The
bearing preload is set by a threaded differential bearing
pinion gear is supported by two tapered roller bearings.
adjusting nut located between the axle housing and dif
The pinion depth is set by a shim pack located
between the pinion gear end and roller bearing. The ferential bearing cap. Two bearing caps hold the differ
pinion bearing preload is set by crushing a collapsible ential in the axle housing.
spacer between the bearings in the axle housing.
4B3-2 9 1/2-INCH RING GEAR
The differential allows the wheels to turn at different 9. Lock bolt (18).
rates of speed while the axle continues to transmit the 10. Lock (16).
driving force. This prevents tire scuffing on turns and • Loosen the adjusting nut (17).
premature wear on internal axle parts. 11. Bearing cap bolts (20).
The axle is sealed with a pinion seal, a seal at each 12. Bearing caps (19).
axle shaft end, and RTV sealant between the cover and • Mark the caps and the housing as left and right.
axle housing.
All corporate rear axles are identified by an alphanu
NOTICE: When prying the differential case
meric broadcast code on the right axle tube near the out of the axle housing, be careful not to
carrier. The axle housing cover does not have a drain
damage the cover gasket surface. The differ
plug.
ential case must be supported when it is
being removed to prevent the case from fall
CHECKING THE AXLE ing and damaging the case.
BEFORE DISASSEMBLY 13. Differential case (27).
• Remove the housing cover and drain the lubricant. • Pry the case from the axle housing at the differ
ential “window” (figure 3).
I? Inspect 14. Bearing outer races (22), shims (21), and adjusting
nut (17).
1. Ring gear backlash. Refer to “Backlash Adjust • Mark the races and the shims as left and right,
ment.” This information can be used to determine and place them with the bearing caps.
the cause of the problem. It will also help when 15. Differential side bearings using J 8107-3 and
setting up the shim packs for locating and preload J 22888-20 (figure 4).
ing the differential case. • The jaws of J 22888-20 must pull from beneath
2. Case for metal chips and shavings. Determine the bearing cone and not the cage. Use the
where these chips and shavings came from, such slots provided for this purpose.
as a broken gear or bearing cage. 16. Ring gear bolts (26).
• Determine the cause of the axle problem before • Ring gear bolts have left-hand threads.
disassembly if possible.
NOTICE: Do not pry the ring gear from the
DISASSEMBLY OF THE case. This will damage the ring gear and the
differential case.
REAR AXLE
17. Ring gear (15) from the differential.
Remove or Disconnect (Figures 1 through 9) • Drive the ring gear off with a brass drift if nec
essary.
Tools Required:
J 8107-3 Differential Side Bearing Puller Plug Inspect
J 22813-01 Axle Bearing Remover
J 2619-01 Slide Hammer • Drive pinion bearing preload with an inch pound
J 22888-20 Differential Side Bearing Remover torque wrench and record for use when reas
J 8614-01 Pinion Flange Remover sembling the pinion (figure 5).
J 22912-01 Rear Pinion Bearing Cone Remover • Pinion assembly for looseness by moving it
• Place the axle in a suitable support. back and forth. Looseness indicates excessive
• Drain the lubricant. bearing wear.
1. The cover bolts (24) and cover (25). 18. Pinion flange nut (6) and washer (7) using
• Refer to “Checking the Axle Before Disassem J 8614-01 to hold the pinion flange (figure 6).
bly.” 19. Pinion flange using J 8614-01 (figure 7).
2. Pinion shaft lock bolt (29) (figure 2). 20. Pinion (15) from the axle housing.
3. Pinion shaft (28). A. Thread the pinion nut halfway onto the pinion.
4. “C” clip (37) from the end of the axle shaft (3). B. Replace the axle housing cover (25) with two
• Push the axle shaft (3) in towards the center of bolts (24) to keep the pinion from falling.
the differential case (27). C. Drive the pinion out of the housing with a ham
5. Axle shaft (3) from the axle housing (12). mer and soft drift (figure 8).
6. Oil seal (4) using a seal removal tool behind the • Remove the cover (25) and the pinion (15).
seal lip. 21. Collapsible spacer (11) from the pinion.
• Be careful not to damage the housing. 22. Outer seal (9) and outer pinion bearing (10).
7. Bearing (5) using J 2619-01 and J 22813-01. 23. Inner bearing (13) and shim (14) from the pinion.
• The tangs of the tool should engage the bear A. Press the bearing off the pinion using
ing outer race. J 22912-01 (figure 9).
8. Pinion (31) and side gears (33). B. Remove the shim.
A. Roll the pinion gears out of the case with the 24. Bearing cups (10 and 13) from the axle housing
pinion thrust washer (30). using a hammer and punch.
B. Remove the side gears (33) and the side gear • Work the cups out of the housing evenly, mov
thrust washers (32). Mark the gears and the ing the punch back and forth between one side
differential case as left and right. of the cup and the other.
9 1/2-INCH RING GEAR 4B3-3
16 1? 19 20
J 8614-3
• The bearing cup bores for nicks or burrs. Remove Bearings for smooth rotation after oiling them.
any that are found. Bearing rollers for wear.
• The housing for cracks. Replace the housing if any Bearing cups for wear, cracks, brinelling, and scor
are found. ing.
• The housing for foreign material such as metal
chips, dirt, or rust. Refer to “Cleaning.” Important
DIFFERENTIAL
When replacing worn or cracked bearings and
Inspect cups, be sure to replace them in sets.
Ring gear and pinion gear for wear. If worn,
Pinion gear shaft for unusual wear. replace them as a set.
Pinion gear and side gear teeth for wear, cracks,
scoring, and spalling. Important
Thrust washers for wear.
The fit of the side gears in the differential case. • Low mileage bearings may have very small
The fit of the side gears on the axle shafts. scratches and pits on the rollers and the bearing
Differential case for cracks and scoring. cups from the initial preload. Do not replace a
All parts for wear and replace if necessary. bearing for this reason.
4B3-6 9 1/2-INCH RING GEAR
F4698
Figure 11—Installing the Rear Pinion Bearing Cup Figure 13— Pinion Depth Tools
9 1/2-INCH RING GEAR 4B3-7
Figure 14— Checking Pinion Depth PINION INSTALLATION (Figures 1, 15 through 18)
Tighten
Tools Required:
J 8107-3 Differential Side Bearing Removal Plug
J 8092 Driver Handle
J 29710 Differential Side Bearing Installer
1. Lubricate all parts with axle lubricant.
2. Side gear thrust washers (32) to the side gears
Figure 17—Installing the Pinion Flange (33). “
Tool Required:
J 24429 Side Bearing Backlash Adjusting
Wrench
J-24429 1. The bearing cups (22) to the differential bearings in
their original locations.
F4733
2. Differential assembly in the axle housing.
Figure 22—Adjusting the Nut 3. Bearing shims (21).
• Push the case away from the pinion towards
the axle housing.
4B3-10 9 1/2-INCH RING GEAR
GEAR TOOTH
PATTERN CHECK
Before final assembly of the differential, a gear tooth
contact pattern check should be performed.
A gear tooth contact pattern check is NOT a substi
tute for adjusting pinion depth and backlash as previ
4. Adjusting nut (17). ously outlined. It is a method to verify the correct
running position of the ring gear and the drive pinion.
A. Tighten the adjusting nut using J 24429.
Gear sets which are not positioned properly may be
B. Turn the pinion to seat the bearings.
noisy, have a short life, or both. With a pattern check,
C. Back off the adjusting nut.
the best contact between the ring gear and the drive
5. Bearing caps (19) and bolts (20) in their original pinion for low noise level and long life can be ensured.
positions.
GEAR TOOTH NOMENCLATURE
A. Assemble the caps loosely.
B. Turn the adjusting nut until the nut contacts the The side of the ring gear tooth which curves outward,
shim. Then tighten the nut three additional slots or is convex, is referred to as the “drive” side (4). The
(figure 22). concave side is the “coast” side (3). The end of the
tooth nearest the center of ring gear is referred to as
Tighten the “toe” end (2). The end of the tooth farthest away
from the center is the “heel” end (1). The toe end of the
• Bolts (20) to 80 N-m (60 lbs. ft.). tooth is smaller than the heel end (figure 24).
BACKLASH ADJUSTMENT
1. Install a dial indicator on the case using a magnetic
base.
2. Place the indicator stem at the heel end of a tooth.
• Set the dial indicator so the stem is in line with
the gear rotation and perpendicular to the tooth
angle.
3. Check and record the backlash at three or four
points around the ring gear (figure 23).
• The pinion must be held stationary when check
ing backlash.
• The backlash should be the same at each point
within 0.05 mm (0.002 inch). If the backlash
varies more than 0.05 mm (0.002 inch), check
for burrs, a distorted case flange, uneven bolt
ing conditions, or foreign matter between the
case and ring gear.
9 1/2-INCH RING GEAR 4B3-11
3. Use the service brake to apply a load until a The position of the drive pinion is adjusted by
torque of 54-68 N-m (40-50 lbs. ft.) is required increasing or decreasing the distance between the pin
to turn the pinion. ion head and the centerline of the ring gear. Decreasing
A test made without loading the gears will not the distance will move the pinion closer to the center-
give a satisfactory pattern. Turn the companion line of the ring gear. Increasing the distance will move
flange with a wrench so that the ring gear the pinion farther away from the centerline of the ring
rotates one full revolution. Then reverse the gear.
rotation so that the ring gear rotates one revolu Backlash is adjusted using side bearing adjusting
shims that move the entire case and ring gear assem
tion in the opposite direction. Excessive turning
bly closer to or farther from the drive pinion. The adjust
of the ring gear is not recommended.
ing shims are also used to set side bearing preload.
4. Observe the pattern on the ring gear teeth and
If the thickness of the right shim is increased (along
compare with figure 25. with decreasing the left shim thickness), backlash will
increase.
ADJUSTMENTS AFFECTING
If the thickness of the left shim is increased (along
TOOTH CONTACT with decreasing the right shim thickness), backlash will
Two adjustments can be made that affects tooth con decrease.
tact pattern; backlash and pinion depth. The effects of FINAL ASSEMBLY
bearing preloads are not readily apparent on hand load
Tools Required:
ed tooth contact pattern tests. However, these adjust
J 8092 Driver Handle
ments should be within specifications before proceeding
J 23765 Axle Shaft Bearing Installer
with backlash and drive pinion adjustments. J 23771 Axle Shaft Seal Installer
J 23911 Pinion Oil Seal Installer
4B3-12 9 1/2-INCH RING GEAR
CONDITION: CONDITION:
• BACKLASH CORRECT. • BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT.
IS TOO FAR AWAY FROM RING GEAR.
TOE TOE
HEEL / \ HEEL HEEL HEEL
\ Jw
\4 L
t f S I
CORRECTION: CORRECTION:
INCREASE THE PINION SHIM THICKNESS. NONE.
CONDITION:
• BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR
IS TOO CLOSE TO RING GEAR.
CORRECTION:
DECREASE THE PINION SHIM THICKNESS.
SERVICE HINTS:
PINION DEPTH SHIM LOCATIONS:
• BETWEEN THE INNER PINION BEARING CONE
AND THE HEAD OF THE PINION GEAR.
• BETWEEN THE INNER PINION BEARING CUP
AND THE REAR AXLE HOUSING.
3704r5056
Important
Tighten
Tighten
HI Tighten
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
9 1/2-INCH RING GEAR AXLE
Fastener N-m Lbs. Ft.
Adjusting Nut Lock Bolt............................................................................................................... 30 22
Axle Cover Bolts........................................................................................................................... 27 20
Bearing Cap Bolts......................................................................................................................... 80 60
Filler Plug....................................................................................................................................... 35 26
Pinion Shaft Lock Bolt................................................................................................................. 36 27
Ring Gear Bolts............................................................................................................................. 145 105
LUBRICATION
Type................................................................................................................................................ 80W-90 GL-5
Capacity.......................................................................................................................................... 2.7 Liters (5.5 Pints)
T2510
9 1/2-INCH RING GEAR 4B3-15
SPECIAL TOOLS
1. J 8 1 0 7 -3 J 22888
2. J 23765 J 24433
3. J 24429 J 22388
7. J8092
. '.-.atfiieO■t
•.
10 1/2-INCH RING GEAR 4B4-1
SECTION 4B4
CONTENTS
SU B JEC T PAGE
General D escription....................................................................................................................................................... 4B4- 1
Checking the Axle Before Disassem bly.............................................................................................................. 4B4- 2
Disassembly of the Rear A x le ................................................................................................................................ 4B4- 2
C lean in g ......................................................................................................................................................................... 4B4- 5
In sp ectio n ......................................................................................................................................................................4B4- 5
Axle H o u sin g ............................................................................................................................................................4B4- 5
D ifferential................................................................................................................................................................. 4B4- 5
Pinion and Ring G ear............................................................................................................................................ 4B4- 5
B earin g s.....................................................................................................................................................................4B4- 5
S h im s.......................................................................................................................................................................... 4B4- 6
Assem bly of the Rear A x le ......................................................................................................................................4B4- 6
Pinion A ssem b ly..................................................................................................................................................... 4B4- 6
Pinion Installation................................................................................................................................................... 4B4- 7
Differential Case A ssem b ly................................................................................................................................. 4B4- 7
Side Bearing Preload A d ju stm en t.................................................. .................................................................. 4B4- 8
Backlash Adjustment............................................................................................................................................. 4B4- 8
Gear Tooth Pattern C heck........................................................................................................................................4B4- 9
Gear Tooth Nomenclature.....................................................................................................................................4B4- 9
Adjustments Affecting Tooth C o n tact..................................................................................................................4B4- 9
Final A ssem b ly............................................................................................................................................................4B4- 9
S pecifications.................................................................................................................................................................. 4B4-11
Fastener Tightening Specifications....................................................................................................................... 4B4-11
Spacer and Shim Specifications............................................................................................................................4B4-11
Lubrication......................................................................................................................................................................4B4-11
Special Tools.....................................................................................................................................................................4B4-12
GENERAL DESCRIPTION
The corporate 10 1/2-inch ring gear rear axle uses a the pinion depth. The pinion bearing preload is set by
conventional ring and pinion gear set to transmit the crushing a collapsible spacer between the front and
driving force of the engine to the rear wheels. This gear rear bearings in the pinion cage.
set transfers this driving force at a 90-degree angle The ring gear is bolted to the differential case with
from the propeller shaft to the axle shafts. left-hand thread bolts.
This axle is full-floating. The axle shaft is supported at The differential case is supported by two tapered roll-
the wheel ends by the wheel hubs. The bolts that attach er bearings. The differential and ring gear are located in
the shaft to the hub also support the axle at the hub. The relationship to the pinion by using two different bearing
splined end of the shaft is supported by the differential. adjusting nuts. These atow the differential to be moved
-p. T ■ u from side to side by adjusting the nuts in or out. The
The p,n,on gear is supported in a pinion cage by differential side be' ri ' ,yoad is accomp|ished by
three bearings; a pinion front bearing, a pinion rear tightening the bearing aM djusting nuts after the ring gear
bearing, and a pilot bearing. The pinion cage is sepa- backlash has been set. Two bearing caps are used to
rate from the axle housing. Selective shims are used t(-,e differential into the axle housing and supply
between the pinion cage and the axle housing to set half of the threads for the bearing adjusting nuts.
4B4-2 10 1/2-INCH RING GEAR
The differential allows the wheels to turn at different 10. Bearings using J 22888-20 (figure 2).
rates of speed while the axle continues to transmit the
A. The jaws of J 22888-20 must pull from beneath
driving force. This prevents tire scuffing on turns and
the bearing cone and not the cage.
premature wear on internal axle parts.
B. Scribe a mark across the differential case.
The axle is sealed with a pinion seal, a gasket at
each axle shaft end, and a gasket between the cover 11. Ring gear bolts (36) and washers (35).
and axle housing.
All corporate rear axles are identified by the alphanu NOTICE: Do not pry the ring gear from the
meric broadcast code on the right axle tube near the case. This will damage the ring gear and the
carrier. The carrier cover does not have a drain plug. differential case.
CHECKING THE AXLE 12. Ring gear (14) from the differential.
BEFORE DISASSEMBLY
• Drive the ring gear off with a brass drift if nec
essary.
Inspect
13. Side gears (29) and thrust washers (30).
Remove the axle cover and drain the axle lubricant. • Mark the gears and the case halves as left and
right.
1. Ring gear backlash. Refer to “Backlash Adjust
ment.” This information can be used to determine 14. Pinion spider (33).
the cause of the axle problem. It will also help 15. Pinion gears (32) and thrust washers (31) from
when setting up the shim packs for locating and the spider (33).
preloading the differential case.
2. Case for metal chips and shavings. Determine 1? Inspect
where these chips and shavings came from; such
as a broken gear or bearing cage. • Drive pinion bearing preload and record (figure
3).
Determine the cause of the axle problem before dis • For looseness of the pinion assembly by mov
assembly if possible. ing it back and forth. Looseness indicates
excessive bearing wear.
DISASSEMBLY OF THE 16. Pinion assembly cage bolts (7) and washers
REAR AXLE (8 ).
17. Pinion cage (10).
+-► Remove or Disconnect (Figures 1 through 9) • Tap on the pilot end of the pinion with a ham
mer and brass drift if necessary.
Tools Required: 18. Pinion cage shims (11).
J 8107 Side Bearing Remover Plug
J 22888-20 Differential Side Bearing Remover A. Keep the shims together for measurement later
in this procedure.
J 8614-01 Pinion Flange Remover
B. Place the pinion cage in a soft-jawed vise.
J 22912-01 Rear Pinion Cone Remover
J 22888-20 Universal Puller 19. Pinion flange nut (1) and washer (2) using
J 8614-01 to hold the flange (figure 4).
Place the axle in a suitable support. 20. Pinion flange using J 8614-01 (figure 5).
1. Cover bolts (25) and cover (24). 21. Pinion (14) from the pinion cage (10).
• Drain the gear lubricant. • Place the cage into an arbor press as shown in
(figure 6) and press the pinion from the cage.
2. Outer axle shaft bolts (46). Do not let the pinion fall.
3. Axle shafts (47).
22. Collapsible spacer (12) from the pinion.
4. Adjusting nut lock bolts (22).
23. Inner bearing (13) from the pinion (14).
5. Adjusting nut lock (21).
• Press the bearing from the pinion using
• Loosen the adjusting nuts (19).
J 22912-01 (figure 7).
6. Bearing cap bolts (28) and washers (27). 24. Pinion seal (5) from the cage.
7. Bearing caps (20).
• Drive the seal from the cage with a hammer
• Mark the caps and the housing as left and right. and punch.
8. Adjusting nuts (19) and bearing cups (18). 25. Front bearing (6) from the cage.
• Mark the nuts and cups as left and right. 26. Bearing cups from the cage.
27. Pilot bearing (15) from the axle housing using a
9. Differential case (34). hammer and brass drift (figure 8).
10 1/2-INCH RING GEAR 4B4-3
F5900
Figure 4— Removing the Drive Pinion Nut Figure 7—Removing the Pinion Inner Bearing
10 1/2-INCH RING GEAR 4B4-5
AXLE HOUSING
1? Inspect
DIFFERENTIAL
e Inspect
Lv Inspect
; Important
L* Inspect
• The nut until the pinion end play is taken up. • Bolts to 88 N m (65 lbs. ft.).
Rotate the pinion while tightening in order to
DIFFERENTIAL CASE ASSEMBLY
seat the bearings. Once there is no end play in
the pinion, the preload torque should be
+«- Install or Connect (Figure 1, 14, and 15)
checked.
• Remove J 8614-01. Using an inch-pound torque
Tools Required:
wrench, check the pinion preload by rotating the
J 24429 Side Bearing Adjustment Spanner
pinion with the wrench. Preload should be at or
below 2.8 to 4.0 N-m (25 to 35 lbs. in.) for new J 8092 Driver Handle
J 8107 Side Bearing Puller Plug
bearings, or 0.56 to 1.7 N m (5-15 lbs. in.) for
used bearings (figure 11).
• If the preload torque is below the values given • Lubricate all parts with axle lubricant.
above, continue torquing the nut in small incre 1. Pinion gears (32) and pinion gear thrust washers
ments. Check the preload after each tightening. (31) to the pinion cross shaft spider (33).
Each tightening increases the bearing preload 2. Differential side gears (29) and side gear thrust
by several pounds. If the bearing preload is washers (30) to the differential case halves in their
exceeded, the pinion will have to be removed, original locations.
and a new collapsible spacer installed. 3. Pinion cross shaft spider (33) to the differential.
• Once the preload has been obtained, rotate the
pinion several times to ensure that the bearings
have seated. Recheck the preload and adjust if
necessary.
10. Pinion cage (10) to the axle housing. Refer to “Pin
ion Installation.”
PINION INSTALLATION
Tools Required:
J 34943 Pinion Pilot Bearing Installer
J 8092 Driver Handle
1. Pinion pilot bearing (15) using J 34943 and J 8092
(figure 12).
A. Bolt the guide plate to the axle housing.
B. Place the bearing (15) onto the guide.
C. Drive the bearing into the housing. The part
number of the bearing must face the pinion
flange.
2. Measure the pinion bearing shims (11). If a new
ring and pinion is installed, the pinion bearing shim
pack must be adjusted.
• Pinion service shims are available in sizes from
0.152 to 0.6096 mm (0.006 to 0.024 inch).
• If the original pinion is being reused, the original
pinion shims should also be reused.
3. Pinion bearing shims (11) to the pinion cage.
• The shims, housing, and cage must be clean.
4. Pinion cage (10) to the axle housing (figure 13).
5. Cage bolts (7).
4B4-8 10 1/2-INCH RING GEAR
4. Case halves.
A. Align the scribe marks on the case halves.
B. Check that the mating surfaces of the differen
tial case and the ring gear are clean and burr
free.
5. Ring gear (14) to the differential (figure 14).
A. Thread two left-hand threaded studs into the
ring gear on opposite sides.
B. Place the ring gear onto the case, and align the
holes in the case with the studs.
C. Press the ring gear onto the case far enough to
start the bolts using J 8107 to protect the differ
ential from the press ram.
6. Ring gear bolts (36).
$ Tighten
Tool Required:
J 24429 Side Bearing Adjustment Wrench
1. Bearing caps (20) to the bearings in their original
locations.
2. Differential assembly to the housing.
3. Adjusting nuts (19).
4. Bearing caps (20) and bolts (28) in their original
positions.
A. Assemble the caps finger tight.
B. Loosen the right side adjusting nut and tighten
the left side nut using J 24429 until the ring
gear contacts the drive pinion (figure 16). Do
not force the gears into contact. This is the zero
lash point.
C. Back off the left adjusting nut approximately two
slots to obtain the initial backlash adjustment.
5. Adjusting nut lock (21) and lock bolt (22) to the left
nut.
A. Do not tighten.
B. Tighten the right adjusting nut firmly to force the
10 1/2-INCH RING GEAR 4B4-9
CONDITION: CONDITION:
• BACKLASH CORRECT. • BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT.
IS TOO FAR AWAY FROM RING GEAR.
TOE TOE
HEEL HEEL HEEL A HEEL
CORRECTION: CORRECTION:
INCREASE THE PINION SHIM THICKNESS. NONE.
CONDITION:
• BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR
IS TOO CLOSE TO RING GEAR.
CORRECTION:
DECREASE THE PINION SHIM THICKNESS.
SERVICE HINTS:
PINION DEPTH SHIM LOCATIONS:
• BETWEEN THE INNER PINION BEARING CONE
AND THE HEAD OF THE PINION GEAR.
• BETWEEN THE INNER PINION BEARING CUP
AND THE REAR AXLE HOUSING.
3704r5056
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
10 1/2-INCH RING GEAR AXLE (CORPORATE)
Fastener N-m Lbs. Ft.
Adjusting Nut Lock Bolts......................................... ................................................................... 30 22
Axle Cover Bolts........................................................................................................................... 27 20
Bearing Cap Bolts......................................................................................................................... 183 135
Filler Plug....................................................................................................................................... 35 26
Pinion Cage to Axle Housing..................................................................................................... 88 65
Ring Gear Bolts............................................................................................................................. 163 120
LUBRICATION
Type 80W-90 GL-5
.4 Liters (7.2 Pints)
T9F>
4B4-12 10 1/2-INCH RING GEAR
SPECIAL TOOLS
J 8614-01
J 8092
J 22888
J 24433
3. 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 Adjustment Spanner
7. Rear Pinion Bearing Cone Remover
J 22912-01
8. Pinion Pilot Bearing Installer (Not Illustrated)
F4662
DANA MODEL 80 (11-INCH RING GEAR) 4B5-1
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. Fasteners that are not reused, and those requiring thread locking compound, will be called out.
The correct torque value must be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................. 4B5- 1
Checking the Axle Before Disassembly.......................................................................................................... 4B5- 2
Disassembly of the Rear Axle........................................................................................................................... 4B5- 2
Cleaning...................................................................................................................................................................4B5- 6
Inspection............................................................................................................................................................... 4B5- 6
Axle Housing......................................................................................................................................................4B5- 6
Differential........................................................................................................................................................... 4B5- 7
Pinion and Ring Gear....................................................................................................................................... 4B5- 7
Bearings.............................................................................................................................................................. 4B5- 7
Shims....................................................................................................................................................................4B5- 7
Assembly of the Rear Axle................................................................................................................................ 4B5- 7
Differential Case Assembly............................................................................................................................ 4B5- 7
Determining Total Shim Pack Size............................................................................................................... 4B5- 8
Pinion Depth Adjustment................................................................................................................................ 4B5- 9
Pinion Installation............................................................................................................................................. 4B5-10
Assembling the Differential into the Axle Housing................................................................................. 4B5-11
Checking Backlash........................................................................................................................................... 4B5-12
Gear Tooth Pattern Check...................................................................................................................................4B5-13
Gear Tooth Nomenclature............................................................................................................................... 4B5-13
Adjustments Affecting Tooth Contact............................................................................................................. 4B5-13
Final Assembly...................................................................................................................................................4B5-13
Specifications............................................................................................................................................................ 4B5-15
Fastener Tightening Specifications...................................................................................................................4B5-15
Ring Gear Bolts.....................................................................................................................................................4B5-15
Available Shim Sizes............................................................................................................................................ 4B5-15
Pinion Bearing and Differential Bearing Preload Specification................................................................ 4B5-15
Lubrication.............................................................................................................................................................. 4B5-15
Special Tools............................................................................................................................................................. 4B5-16
GENERAL DESCRIPTION
The Dana 11-inch ring gear rear axle uses a conven This axle is full-floating. The axle shafts are support
tional ring and pinion gear set to transmit the driving ed at the wheel ends by the wheel hubs. The shaft at
force of the engine to the rear wheels. The gear set the wheel end is supported and splined to the hub
transfers the driving force at a 90 degree angle from the inner-diameter. The other splined end of the shaft is
propeller shaft to the axle shafts. supported by the differential.
4B5-2 DANA MODEL 80 (11-INCH RING GEAR)
The pinion gear is supported by two tapered roller CHECKING THE AXLE
bearings. The pinion depth is set by a shim pack
between the inner pinion bearing cup and axle housing. BEFORE DISASSEMBLY
The pinion bearing preload is set by a shim pack at the 1. Remove the cover and drain the lubricant.
front of the axle housing between the bearing cone and
L* Inspect
pinion gear.
The ring gear bolts to the differential case.
2. Ring gear backlash. Refer to “Backlash Adjust
The differential case is supported by two tapered roll ment.”
er bearings. The differential bearing preload and drive • This information can be used to determine the
gear to pinion gear backlash is controlled by two meth cause of the axle problem. It will also help when
ods. One method uses a 0.76 mm (0.030 inch) hard setting up the shim packs for locating and preload
ened shim located between each differential bearing ing the differential case.
cone and the differential case, and a selective outboard 3. Case for metal chips and shavings. Determine
spacer shim located between each differential bearing where these chips and shavings came from, such
cup and housing. The other method uses selective as a broken gear or bearing cage.
shims between each differential bearing cone and the • Determine the cause of the axle problem before
differential case, with outboard spacers between each disassembly, if possible.
differential bearing cup and housing. To move the ring
gear with outboard selective shims, choose shims of DISASSEMBLY OF THE
different thickness to accommodate the change. For REAR AXLE
example: if a shim that is 0.13 mm (0.005 inch) thinner
is required on the ring gear side, then one that is 0.13 4--4 Remove or Disconnect (Figures 2 through 13)
mm (0.005 inch) thicker will be required on the opposite
side. If the change is required on a axle that is built Tools Required:
using the other method, gear movement may be J 8107-3 Side Bearing Puller Plug
accomplished by moving shims from one side of the J 8614-01 Pinion Flange Holder
differential case to the other. If the differential preload J 24385-01 Differential Housing Spreader
needs to be changed, equal amounts must be added or J 29721 Differential Side Bearing Remover
subtracted from each side. J 29721-70 Side Bearing Adapters
The axle housing is spread to remove the differential C 4171 Universal Handle
from the housing. When the spreader is removed, the C 4307 Bearing Cup Remover (Outer)
D 128 Dial Indicator Set or Equivalent
housing sets the bearing preload.
D 158 Bearing Cup Remover
Two bearing caps hold the differential in the axle
housing. CAUTION: When disassembling the carrier,
The axle is sealed with a pinion seal, hub seal, and make sure the entire axle is held tight in an
RTV between the cover and the housing. approved stand or rack. Improperly support
All Dana axles are identified by a part number and ed axles can cause serious injury.
manufacturing date on the right axle tube, cover plate • Place the axle in a suitable support.
side. The model number is cast on the carrier. The axle 1. Bolts (17) and cover (14).
ratio and Limited Slip lubrication information are located • Drain the lubricant.
on tags attached to the differential cover plate. The 2. Axle shafts far enough to clear the differential case.
carrier does not have a drain plug. 3. Bearing cap bolts (19).
MANUFACTURING
DATE
PART NUMBER
MODEL NUMBER
RATIO TAG
LIMITED SLIP
LUBRICATION TAG V3124
V3943-
4. Bearing caps (18). CAUTION: Do not allow the case to fall. It can
strike legs or feet and may cause serious
A. Corresponding letters are stamped on the caps injury. Also, gear teeth may have sharp
and axle housing. The caps must be reassem edges. When handling, use care to avoid cut
bled exactly as removed. ting hands.
B. Assemble J 24385-01 to the differential housing
as shown in (figure 3). 5. Case (22) from the housing (1) using two pry bars
C. Assemble the dial indicator. (figure 4).
Preset the gage at least 5 mm (0.200 inch), 6. J 24385-01 from the housing (1).
7. Bearing cups (20).
then rotate the indicator housing to zero the
• Mark the cups left and right, and place them
dial.
with the proper bearing caps.
8. Bearings (20) using J 8107-3, J 29721, and
NOTICE: Do not spread the axle housing J 29721-70 (figure 5).
more than 0.38 mm (0.015 inch). Overspread • Mark the bearings left and right, and place them
ing the housing can damage or distort it. with their corresponding bearing caps.
9. Shims (21).
• Mark the shims left or right.
D. Spread the housing while examining the dial • Check outboard spacers for damage (e.g. bent,
indicator. Do not spread the housing more than or deep grooves caused by worn bearings). If
0.38 mm (0.015 inch). damaged, they should be replaced with new
ones at time of reassembly.
• Note the ring gear fastener strength for later
use. Refer to “Specifications” at the rear of this
section.
10. Ring gear bolts (23) and discard.
Important
Figure 4 — Removing the Differential Figure 5— Removing the Differential Side Bearings
DANA MODEL 80 (11-INCH RING GEAR) 4B5-5
I? Inspect
I9 Inspect
NOTICE: You may use the older style gage Figure 18—Master Pinion Block
set if you already have them. The new style
gages use the bearings as part of the gage 7. Place D 115 onto the height block (figure 19).
system, while the older style uses a Master • Place the gage on the upper step of the height
Block that acts as a Master Bearing. block. Apply pressure to the gage block, push
ing down on the height block. While applying
pressure, set the dial indicator at zero.
1. Clean the carrier bores and all tools. The pinion
8. Slide the gage over the arbor (figure 20).
bore must be free of nicks and dirt. 9. Record the reading at the point of greatest deflec
2. Drive the inner bearing cup into the axle assembly tion (when the dial indicator needle is centered
using C 4171 and C 4204. The cup must be seat between movement to the left and right).
ed.
A. This reading indicates the amount of shims
3. Drive the outer bearing cup into the axle assembly
needed for a nominal pinion setting. The pinion
using J 7818 and J 8092 (figure 17). marking may change the pinion depth by
4. Assemble inner bearing cone into cup. adding or deleting shims from the nominal pin
5. Assemble master pinion block 6738, pinion height ion setting.
block 6739 into carrier housing using adapter cone B. A positive (+) pinion marking indicates that the
6740 and screw 6741 (figure 18). The outer bear distance between the ring gear centerline and
ing cone will be used with the adapter cone and the pinion head must increase by the number of
should be assembled at this time. thousandths marked on the pinion. This means
6. Hand tighten the cone until all end-play is removed that the shim pack will decrease by the same
from gage assembly. number of thousandths.
Figure 17 Installing Outer Pinion Bearing Cup Figure 19—Dial Indicator On The Height Block
4B5-10 DANA MODEL 80 (11-INCH RING GEAR)
D 6732
D 115-3
Figure 20— Dial Indicator On The Arbor
PINION INSTALLATION
6. Force the differential case away from the pinion 12. Assemble J 24385-01 to the axle (figure 27).
gear to obtain an indicator reading. Repeat this 13. Assemble the dial indicator. Preset the gage at
action until a consistent reading is obtained. least 0.05 mm (0.020 inch), then rotate the indica
Record the reading. tor housing to zero the dial.
7. Remove the indicator and the differential case from
the axle housing. NOTICE: Do not spread the axle housing
8. Remove the master bearings from the differential more than 0.38 mm (0.015 inch). Over-spread
case. ing can damage or distort the housing.
9. Using the total shim pack size determined earlier,
(Refer to “Determining Total Shim Pack Size”) sub 14. Spread the housing while examining the dial indi
tract the reading found in step 6 from the total cator.
reading. The reading found in step 6 will be the 15. Remove the dial indicator.
shim size on the ring gear side. The remaining 16. Place the bearing cups (20) onto the bearings.
portion of the shim pack will be used on the side 17. Install the differential assembly into the carrier.
opposite the ring gear. Add an additional 0.25 mm • Use a soft-faced hammer to seat the differential
(0. 010 inch) of shims to the side opposite the ring assembly in the axle housing.
gear to preload the bearings. 18. Remove the spreader.
10. Place the proper shims on the differential side of 19. Install the bearing caps (18) in their original posi
bearing hub (ring gear side) and drive the differen tions.
tial bearing onto the hub using J 8092 and J 23690 20. Install the bearing cap bolts (19).
(figure 26).
$ Tighten
Important
• Bolts (19) to 115 N-m (85 lbs. ft.).
• If the axle assembly uses the outboard selective
spacers, place the 0.76 mm (0.030 inch) shim on CHECKING BACKLASH
the hub that was used along with the master bear 1. Mount a dial indicator with a magnetic base to the
ings to make the measurement. Then select the axle housing (figure 28).
appropriate outboard selective spacer and assem 2. Place the indicator tip at the heel end of the tooth.
ble into housing. 3. Check the backlash at three equally spaced points.
11. Place the proper shims on the differential side T h e b a c k l a s h s h o u l d be 0 . 1 3 - 0 . 2 3 mm
bearing hub (opposite the ring gear) and drive the (0.005-0.009 inch). The measurement must not
differential bearing onto the hub using J 8092 and vary more than 0.05 mm (0.002 inch) between the
J 23690. points checked.
A. High backlash is corrected by moving the ring
Important gear closer to the pinion.
B. Low backlash is corrected by moving the ring
If the axle assembly uses the outboard selective gear away from the pinion.
spacers, place the 0.76 mm (0.030 inch) shim on 4. To adjust the backlash, the differential case must
the hub that was used along with the master bear be removed from the housing, and the shims
ings to make the measurement. Then select the adjusted from one side to the other. For example: if
appropriate outboard selective spacer and assem the shim thickness needs to be reduced on the ring
ble into housing. gear side by 0.13 mm (0.005 inch), then 0.13 mm
(0.005 inch) must be added to the other side. If tion in the opposite direction. Excessive turning
backlash is correct and the preload must be of the ring gear is not recommended.
changed, then change each side by an equal 4. Observe the pattern on the ring gear teeth and
amount. compare with figure 30.
5. Make the final gear pattern check.
ADJUSTMENTS AFFECTING
GEAR TOOTH TOOTH CONTACT
PATTERN CHECK
Two adjustments can be made that affect tooth con
Before final assembly of the differential, a gear tooth tact pattern: backlash and drive pinion depth. The
contact pattern check should be performed. effects of bearing preloads are not readily apparent on
A gear tooth contact pattern check is NOT a substi hand loaded tooth contact pattern tests; however, these
tute for adjusting pinion depth and backlash as previ adjustments should be within specifications before pro
ously outlined. It is a method to verify the correct ceeding with backlash and drive pinion adjustments.
running position of the ring gear and the drive pinion. The position of the drive pinion is adjusted by
Gear sets which are not positioned properly may be increasing or decreasing the distance between the pin
noisy, have a short life, or both. With a pattern check, ion head and the centerline of the ring gear. Decreasing
the best contact between the ring gear and the drive the distance will move the pinion closer to the center-
pinion for low noise level and long life can be ensured. line of the ring gear. Increasing the distance will move
GEAR TOOTH NOMENCLATURE the pinion farther away from the centerline of the ring
gear.
The side of the ring gear tooth which curves outward, Backlash is adjusted by means of the side bearing
or is convex, is referred to as the “drive” side (4). The adjusting shims that move the case and ring gear
concave side is the “coast” side (3). The end of the assembly closer to, or farther from, the drive pinion.
tooth nearest the center of ring gear is referred to as (The adjusting shims are also used to set side bearing
the “toe” end (2). The end of the tooth farthest away preload).
from the center is the “heel” end (1). The toe end of the If the thickness of the right shim is increased (along
tooth is smaller than the heel end (figure 29). with an equal decrease in the left shim thickness),
TEST backlash will increase.
If the thickness of the left shim is increased (along
1. Wipe oil out of axle housing and carefully clean with an equal decrease in the right shim thickness),
each tooth of the ring gear. backlash will decrease.
2. Apply gear marking compound sparingly to all
ring gear teeth using a medium stiff brush. FINAL ASSEMBLY
3. Use the service brake to apply a load until a
torque of 54-68 N-m (40-50 lbs. ft.) is required ■44- Install or Connect
to turn the pinion.
A test made without loading the gears will not
give a satisfactory pattern. Turn the companion Tighten
flange with a wrench so that the ring gear
$
rotates one full revolution. Then reverse the Cover bolts (17) to 47 N-m (35 lbs. ft.
rotation so that the ring gear rotates one revolu
4B5-14 DANA MODEL 80 (11-INCH RING GEAR)
CONDITION: CONDITION:
• BACKLASH CORRECT. • BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT.
IS TOO FAR AWAY FROM RING GEAR.
TOE TOE
HE HEEL A HEEL
CORRECTION: CORRECTION:
INCREASE THE PINION SHIM THICKNESS. NONE.
CONDITION:
• BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR
IS TOO CLOSE TO RING GEAR.
CORRECTION:
DECREASE THE PINION SHIM THICKNESS.
SERVICE HINTS:
PINION DEPTH SHIM LOCATIONS:
• BETWEEN THE INNER PINION BEARING CONE
AND THE HEAD OF THE PINION GEAR.
• BETWEEN THE INNER PINION BEARING CUP
AND THE REAR AXLE HOUSING.
3704r5056
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Nm Lbs. Ft.
Axle Cover Bolts............................................................................................................................. 47 35
Bearing Cap Bolts........................................................................................................................... 115 85
Drive Pinion Nut
Model 8 0 ...................................................................................................................................... 637 470
Fill Plug............................................................................................................................................ 33 24
RING GEAR BOLTS
Model N-m Lbs. Ft.
80......................................... ............................................................................................................. 298 220
AVAILABLE SHIM SIZES
Differential Bearing Adjusting Shim............................................................. ...................................... 0.0762mm (0.003-inch)
0.127mm (0.005-inch)
0.254mm (0.010-inch)
0.762mm (0.030-inch)
Outer Pinion Bearing Preload Shim................................................................................................... 0.3556mm (0.014-inch)
0.381mm (0.015-inch)
0.4064mm (0.016-inch)
0.4572mm (0.018-inch)
0.508mm (0.020-inch)
0.5334mm (0.021-inch)
0.5588mm (0.022-inch)
0.5842mm (0.023-inch)
0.762mm (0.030-inch)
Inner Pinion Bearing Shim .................................................................................................................. 0.0762mm (0.003-inch)
0.127mm (0.005-inch)
0.254 mm (0.010-inch)
Inner Pinion Bearing Shim ......................................................................................................................................... 0.005-inch
0.010-inch
Selective Outboard Spacers.................................................................................................................. 5.18mm (0.2040-inch)
5.26mm (0.2070-inch)
5.33mm (0.2100-inch)
5.41mm (0.2130-inch)
5.49mm (0.2160-inch)
5.56mm (0.2190-inch)
5.64mm (0.2220-inch)
5.72mm (0.2250-inch)
5.79mm (0.2280-inch)
5.87mm (0.2310-inch)
5.94mm (0.2340-inch)
6.02mm (0.2370-inch)
6.10mm (0.2400-inch)
Inboard Shim.............................................................................................................................0.84/0.69mm (0.33/0.027-inch)
(Used with selective outboard shims)
Outboard Spacers (Non Selective Type)................................................................................4.98/4.88mm (.196/. 192-inch)
(used with differential bearing adjusting shims 0.076, 0.127, 0.254, 0.762 mm (0.003, 0.005, 0.010, 0.030 inch)
PINION BEARING AND DIFFERENTIAL
BEARING PRELOAD SPECIFICATION
Torque to Rotate Drive Pinion Only N-m Lbs. In.
New bearings.............................................................................................................................. 2.8-5.1 25-45
Ratios 4.63 to 5.13.............................................................................................................................68-.90 6-8
Torque to Rotate Drive Pinion and Differential Case (Less Axle Shafts, New Bearings). 2.26-4.52 20-40
Additional Torque to Rotate Required for Differential Bearing Preload (new bearings
only) by Ratio: 4.63 to 5.13
LUBRICATION
Capacity.......................................................................................................................................................4.0 Liters (8.2 Pints)
Type..................................................................................................................................... SAE 80-W-90 GL5 Gear Lubricant
T3038
4B5-16 DANA MODEL 80 (11-INCH RING GEAR)
SPECIAL TOOLS
1. D 116-2
2. D 115-3 11, J 8092
12. J 5590
D 116-1
14. J 23690
5. D 136/D 346
15. J 29721
6. D 6255
16. J 24385-01
7. C 4204
17. J 29721-70
<0<S>
8. C 4171
J 8107-03
10. J 7818
V3951
LOCKING DIFFERENTIAL 4B7-1
SECTION 4B7
LOCKING DIFFERENTIAL
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to CAUTIONS in
Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring Location view in Section 9J
before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could
result in possible air bag deployment, personal injury, or otherwise unneeded SIR system 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. Fasteners that are not reused, and those requiring thread locking compound will be called out.
The correct torque value must be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
SUBJECT PAGE
Locking Differentials................................................................................................................................................ 4B7- 2
7 5/8, 8 1/2, 8 5/8 and 9 1/2-Inch Ring G ear................................................................................................. 4B7- 2
Disassembly of the Differential......................................................................................................................4B7- 2
Cam Unit Disassembly - 7 5/8, 8 1/2 and 8 5/8-Inch............................................................................... 4B7- 2
Cam Unit Disassembly - 9 1/2-Inch.............................................................................................................. 4B7- 3
Cleaning and Inspection................................................................................................................................. 4B7- 3
Cam Unit Assembly - 7 5/8 8 1/2 and 8 1/2-Inch......................................................................................4B7- 4
Cam Unit Assembly - 9 1/2-Inch................................................................................................................... 4B7- 4
Adjustment of the Differential........................................................................................................................4B7- 4
Assembly of the Differential........................................................................................................................... 4B7- 5
10 1/2-Inch Ring Gear.......................................................................................................................................... 4B7- 6
Disassembly of the Differential......................................................................................................................4B7- 6
Cleaning and Inspection................................................................................................................................. 4B7- 7
Cam Unit Assembly.......................................................................................................................................... 4B7- 7
Adjustment of the Differential........................................................................................................................4B7- 8
Assembly of the Differential........................................................................................................................... 4B7- 9
Specifications............................................................................................................................................................ 4B7-10
Fastener Tightening Specifications.................................................................................................................. 4B7-10
Thrust Block Sizes............................................................................................................................................... 4B7-10
Reaction Block Size - 10 1/2-Inch.....................................................................................................................4B7-10
Right Side Gear Thrust W asher........................................................................................................................4B7-10
Reaction Block Thrust Washers........................................................................................................................4B7-10
Lubrication.............................................................................................................................................................. 4B7-10
Special Tools............................................................................................................................................................. 4B7-11
4B7-2 LOCKING DIFFERENTIAL
LOCKING DIFFERENTIALS
7 5/8, 8 1/2, 8 5/8 AND 8. Pinion shaft (18).
9. Differential pinion gears (7) and pinion thrust wash
9 1/2-INCH RING GEAR ers (6).
DISASSEMBLY OF THE DIFFERENTIAL • Roll the gears out of the case by rotating one of
the side gears.
Remove or Disconnect (Figures 1 through 7) 10. Thrust block (17).
11. Right side gear (10).
Tools Required: 12. Right clutch plates (9) and side thrust washer.
J 26252 Governor Remover 13. Left side gear (21), cam plate (16), and clutch
1. Governor bushing (4) using J 26252 (figure 2). plates (12) as an assembly (cam unit).
2. The E-clips that hold the latching bracket in place 14. Side gear thrust washer (13).
on the bracket shaft. CAM UNIT DISASSEMBLY -
• Move the bracket down the shaft. 7 5/8, 8 1/2 AND 8 5/8-INCH
3. Latching bracket bushing (5) using J 26252.
4. Latching bracket (5), shaft, and spring from the Remove or Disconnect (Figures 1 and 3)
case.
5. Governor assembly (11) from the case. 1. Retaining ring (22) (figure 3).
6. Stop pin (2) (9 1/2-inch only). 2. Clutch plates (12).
7. Lock screw (3). 3. Guide clips (20).
Figure 2— Removing the Governor Bushings Figure 4— Removing the Thrust Sleeve
Figure 3—Removing the Retaining Ring Figure 5—Checking Cam Gear Backlash
4. Wave washer (15). CLEANING AND INSPECTION
5. Cam plate (16).
6. Side cam gear (21). Py[ Clean
CAM UNIT DISASSEMBLY - 9 1/2-INCH
• All parts with an approved solvent.
Remove or Disconnect (Figures 1 and 4)
Inspect
Tools Required:
J 22912-01 Bearing Remover • All parts for excessive wear or breakage and
• Measure and record the overall length of the gear
replace if necessary.
assembly from the front of the gear to the back of
• Pinion gear and side gear teeth for wear, cracks,
the side thrust sleeve (14) including the side gear
scoring, and spalling.
thrust washer(13).
• Thrust washer for wear.
1. Guide clips (20).
2. Side thrust sleeve (14) using J 22912-01. • The fit of the side gears on the axle shafts.
• Press the sleeve from the side gear (figure 4). • Differential case for cracks and scoring.
3. Clutch plates (12). • Thrust sleeve for excessive wear. Do not replace
4. Wave washer (15). the thrust sleeve unless necessary. Inspect the
5. Cam plate (16). side gear bore for scoring. If scoring is present,
6. Side cam gear (21). replace the entire differential.
4B7-4 LOCKING DIFFERENTIAL
Figure 6— Measuring Side Gear Spread Figure 7— Measuring the Thrust Block
CAM UNIT ASSEMBLY - 7 5/8, 8 1/2 AND 8 5/8-INCH ADJUSTMENT OF THE DIFFERENTIAL
• If it is necessary to replace the cam gear, right side
«*<- Install or Connect (Figures 1 and 3) gear, or thrust block, the entire differential must be
adjusted. The differential is adjusted by using
1. Cam plate (16) to the side cam gear (21). selective thickness thrust washers behind each
2. Wave washer (15). side gear and selective thickness reaction blocks.
3. Clutch plates (12) (7 5/8 = 8 plates. 8 1/2 and 8 5/8 • It is important to build up the differential properly.
= 10 plates). The proper clearance between parts is critical to
• Alternate the plates as shown in figure 1. the operation of the unit.
• There are three adjustments needed:
4. Retaining ring (22) (figure 3). (1) Left side gear backlash.
5. Guide clips (20) to the clutch plates (12). (2) Right side gear backlash.
• Use grease in the clips to hold them in place on (3) Thrust block clearance.
the plates. Left Side Gear Backlash Adjustment
CAM UNIT ASSEMBLY - 9 1/2-INCH 1. Install the cam unit and side thrust washer (13) to
the flange end of the case.
Install or Connect 2. Place the pinion gears (7) and side gear thrust
washers into the differential.
1. Cam piate (16) to the side cam gear (21). • Align them with the pinion shaft hole.
2. Wave washer (15). 3. Press down the side gear, and install the pinion
3. Clutch plates (12). shaft (18) and lock screw (3).
• If the side gear cannot be pressed down far
• Alternate the plates as shown in figure 1. enough to install the pinion shaft, replace the
4. Thrust sleeve (14). side gear thrust washer with a thinner washer.
4. Rotate the pinion gear closest to the lock screw so
• Press the thrust sleeve flush with the side gear
one of the teeth is pointing downward (perpendicu
disc splines. lar to the ring gear flange).
5. Guide clips (20) to the clutch plates (12). 5. Insert a large tapered tool, like a screwdriver, firmly
between the side gear and the pinion shaft.
• Use grease in the clips to hold them in place on
6. Mount a dial indicator to the ring gear flange and
the plates.
place the stem of the indicator on one of the teeth
A. If the side cam gear or side thrust sleeve has on the pinion gear closest to the lock screw (figure
been replaced, measure and record the overall 5).
length of the gear assembly from the front of 7. Pull the pinion gear firmly into its seat, and rotate
the gear to the back of the side thrust sleeve the gear back and forth while reading the dial indi
(14) including the side gear thrust washer (13). cator. Record the reading.
B. Compare this reading with the reading obtained 8. Repeat steps 4 through 7 on the opposite pinion
earlier in this section. gear.
C. If the new reading is more than 0.0762 mm 9. The backlash should be between 0.254 and 0.457
(0.003 inch) higher or lower than the original, mm (0.010 and 0.018 inch).
select a thrust washer that will return the read 10. If the backlash is too high, use a thicker side gear
ing closest to the original reading. thrust washer.
LOCKING DIFFERENTIAL 4B7-5
Thrust Block Clearance Adjustment 10. Stop pin (2) (9 1/2-inch only).
• Press the pin flush with the case.
Install or Connect (Figures 1, 6, and 7)
€ Measure
31. Differential Case Halves 37. Plates 43. Governor and Latching Bracket
32. Screw 38. Pinion Thrust Washer 44. Plates
33. Cam Plate 39. Pinion Gear 45. Side Gear Thrust Washer
34. Guide Clip 40. Side Cam Gear 46. Side Gear
35. Thrust Sleeve 41. Reaction Block 47. Guide Clip
36. Side Gear Thrust Washer 42. Pinion Yoke 48. Governor
F5915
Tools Required:
J 22912-01 Bearing Remover
1. The ring gear and differential side bearings. Refer
to “Disassembly of the Rear Axle” in “10 1/2-Inch
Rinq Gear.” Figure 10— Differential Case Halves
LOCKING DIFFERENTIAL 4B7-7
Figure 11— Removing the Thrust Sleeve Figure 12—Cam Unit Components
ADJUSTMENT OF THE DIFFERENTIAL 3. Place the pinion gears and pinion thrust washers
• If it is necessary to replace the cam gear, the right on the pinion yoke.
hand side gear, or the reaction blocks, the entire 4. Install the yoke firmly to the differential case half
differential must be adjusted. The differential is (figure 14).
adjusted using selective thickness thrust washers 5. Loosen the nut, and index one pinion gear tooth to
behind each side gear, and selective thickness point downward (perpendicular to the case half
thrust washers between the reaction blocks. face). Tighten the nut.
• It is important to build up the differential properly. 6. Mount a dial indicator on the case half face using a
The proper clearance between parts is critical to magnetic base (figure 15).
the operation of the unit. 7. Place the stem of the dial indicator on the pinion
• There are three adjustments needed: gear tooth.
(1) Left side gear backlash. 8. Pull the pinion gear firmly into its seat, and rotate
(2) Right side gear backlash. the gear back and forth while reading the dial indi
(3) Thrust block clearance. cator. Record the reading.
• Do not unseat the pinion yoke. This will make
Right Side Gear Backlash Adjustment the backlash reading inaccurate.
1. Install the cam unit and side gear thrust washer 9. Repeat steps 5 through 8 on the remaining 2 pin
(36) to the right case half. ions.
2. Clamp the cam unit in place using a set of wash 10. The backlash should be between 0.254 and 0.457
ers, nut, and a bolt long enough to hold the cam mm (0.010 and 0.018 inch).
unit in place (figure 13). 11. If the backlash is too high, use a thicker side gear
thrust washer.
12. If the backlash is too low, use a thinner side gear
thrust washer.
* Measure
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener N-m Lbs. Ft.
Differential Lockscrew
7 5/8, 8 1/2 and 8 5/8-inch 36 27
9 1/2-inch..................... 50 37
THRUST BLOCK SIZES
Color Code 7 5/8-Inch 8 1/2 and 8 5/8-Inch 9 1/2-lnch
Purple............................ 1.260- nch 1.322-inch 1.598-inch
White............................. 1.264- nch 1.326-inch 1.602-inch
Brown............................ 1.268- nch 1.330-inch 1.606-inch
Yellow........................... 1.272- nch 1.334-inch 1.610-inch
Orange......................... 1.276- nch 1.338-inch 1.614-inch
Pink.............................. 1.280- nch 1.342-inch 1.618-inch
Green........................... 1.284- nch 1.346-inch 1.622-inch
Blue.............................. 1.288- nch 1.350-inch 1.626-inch
Black............................ — — 1.630-inch
REACTION BLOCK SIZE — 10 1/2-INCH
0.787-inch
RIGHT SIDE GEAR THRUST WASHER
7 5/8, 8 1/2, 8 5/8 and 9 1/2-Inch Axles 10 1/2-lnch Axles
0.010- nch 0.022-inch
0.015- nch 0.027-inch
0.020- nch 0.032-inch
0.025- nch 0.036-inch
0.030- nch 0.040-inch
0.035- nch 0.042-inch
0.040- nch 0.044-inch
0.045- nch 0.048-inch
0.052-inch
REACTION BLOCK THRUST WASHERS
0.787-inch
0.022 0.030 0.038 0.046
0.023 0.031 0.039 0.047
0.024 0.032 0.040 0.048
0.025 0.033 0.041 0.049
0.026 0.034 0.042 0.050
0.027 0.035 0.043 0.051
0.028 0.036 0.044 0.052
0.029 0.037 0.045
REACTION BLOCK THRUST WASHERS
7 5/8-Inch 8 1/2 and 8 5/8-Inch 9 1/2-lnch 10 1/2-lnch
0.022-inch 0.022-inch 0.022-inch 0.010-inch
0.027-inch 0.027-inch 0.027-inch 0.015-inch
0.032-inch 0.032-inch 0.032-inch 0.020-inch
0.036-inch 0.036-inch 0.036-inch 0.025-inch
0.040-inch 0.040-inch 0.040-inch 0.030-inch
— — 0.042-inch 0.035-inch
0.044-inch 0.044-inch 0.044-inch 0.040-inch
0.048-inch 0.048-inch 0.048-inch 0.045-inch
0.052-inch 0.052-inch 0.052-inch
LUBRICATION
Lubricant .................................. 80W90 GL-5
(Do not use limited slip additive)
T3324
LOCKING DIFFERENTIAL 4B7-11
SPECIAL TOOLS
NOTES
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1-1
SECTION 4C1
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................4C1- 2
Disassembly of The Axle........................................................................................................................................ 4C1- 2
Inspection............................................................................................................................................................... 4C1- 2
Disassembly........................................................................................................................................................... 4C1- 2
Part-Time Front Drive Axle............................................................................................................................. 4C1- 2
All Wheel Drive (AWD) Front Axle................................................................................................................ 4C1- 7
Cleaning and Inspection......................................................................................................................................... 4C1- 8
Cleaning...................................................................................................................................................................4C1- 8
Inspection................................................................................................................................................................4C1- 8
Axle Housing...................................................................................................................................................... 4C1- 8
Differential........................................................................................................................................................... 4C1- 8
Ring and Pinion Gear....................................................................................................................................... 4C1- 8
Bearings.............................................................................................................................................................. 4C1- 9
Thrust Washers, Shims and Adjuster Sleeves.......................................................................................... 4C1- 9
Shift Mechanism.................................................................................................................................................4C1- 9
Assembly of The Axle............................................................................................................................................. 4C1- 9
Differential Case Assembly.................................................................................................................................4C1- 9
Pinion Bearing Cup Installation........................................................................................................................4C1- 9
Pinion Depth Adjustment....................................................................................................................................4C1-10
Pinion Installation..................................................................................................................................................4C1-11
Differential Assembly Installation...................................................................................................................... 4C1-12
Adjusting Backlash.............................................................................................................................................. 4C1-12
Gear Tooth Contact Pattern Check...................................................................................................................4C1-13
Gear Tooth Nomenclature............................................................................................................................... 4C1-13
Test........................................................................................................................................................................ 4C1-13
Adjustments Affecting Tooth Contact.......................................................................................................... 4C1-14
Final Assem bly......................................................................................................................................................4C1-14
Part-Time Front Drive Axle............................................................................................................................. 4C1-14
All Wheel Drive (AWD) Front Axle................................................................................................................ 4C1-16
Drive Axle Assembly................................................................................................................................................4C1-17
Outer Deflector Ring............................................................................................................................................ 4C1-17
ABS Sensor Ring...................................................................................................................................................4C1-17
Outer Joint Seal.....................................................................................................................................................4C1-17
Outer Joint Assembly.......................................................................................................................................... 4C1-20
Inner Tripot S eal....................................................................................................................................................4C1-21
Specifications............................................................................................................................................................ 4C1-23
Fastener Tightening Specifications...................................................................................................................4C1-23
Available Shim Sizes............................................................................................................................................ 4C1-23
Pinion Preload and Backlash............................................................................................................................ 4C1-23
Lubrication.............................................................................................................................................................. 4C1-23
Special Tools.................................................................................................................................. .......................... 4C1-24
4C1-2 7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE
GENERAL DESCRIPTION
The axle used on T model vehicles has a center bearing that is pressed onto the pinion. The pinion
disconnect feature which allows shifting into and out of bearing preload is set by crushing a collapsible spacer
four wheel drive when the vehicle is in motion under between the pinion bearings in the axle housing.
most conditions. The ring gear is bolted to the differential case with
The front axle on the all wheel drive model uses a left-hand thread bolts.
full-time four-wheel drive system, with no disengage The differential case is supported in the axle housing
by two tapered roller bearings. The differential and ring
ment feature.
gear are located in relationship to the pinion by thread
The axle uses a conventional ring and pinion gear set
ed adjusters.
to transmit the driving force of the engine to the wheels.
The differential allows the wheels to turn at different
The gear set transfers the driving force at a 90-degree rates of speed while the front axle continues to transmit
angle from the propeller shaft to the axle shafts. the driving force. This prevents tire scuffing while turn
The pinion gear is supported by two tapered roller ing and premature wear on internal axle parts.
bearings. The pinion depth is set by a shim pack locat The alphabetic identification code is located on a tag
ed between the gear end of the pinion and the roller attached to the right axle tube.
PART-TIME FRONT DRIVE AXLE • Insert a screwdriver into the slots provided and
pry to separate the case (figure 7).
* Disassemble (Figure 1 and 3 through 17) 17. Differential case.
18. Bolts and lock tabs from the side bearing adjuster
Tools Required: sleeves (figure 8).
J 2619-01 Slide Hammer
19. Bearing cups and sleeves from the case.
J 29369-2 Axle Tube Bearing Remover
J 8614-01 Pinion Flange Remover • Turn the sleeves using J 33792 until the cups
J 21551 Bearing Remover are pushed out of the case (figure 9).
J 22912-01 Pinion Bearing Remover
J 23907 Slide Hammer 20. Bearings from the sleeves. Use J 21551 (figure
J 33791 Bushing Remover 10).
J 33792 Side Bearing Adjuster Wrench 21. Pinion flange nut and washer using J 8614-01 (fig
J 33837 Pinion Bearing Cup Remover Kit ure 11).
J 34011 Output Shaft Pilot Bearing Remover • Mount the left carrier case half in J 33837-1
1. Bolts, shift cable housing, and spring. (figure 12).
2. Tube, and thrust washer.
3. Spring, and shift shaft with fork. 22. Flange and deflector using J 33837 -1 and
4. Axle shaft with deflector. J 33837-3 (figure 12).
A. Clamp the axle tube in a vise. Clamp ONLY on 23. Pinion, with spacer, pinion bearing and shim.
the mounting flange. 24. Spacer from the pinion.
B. Strike the inside of the shaft flange with a brass 25. Bearing from the pinion. Use J 22912-01 and a
hammer to dislodge the shaft. press (figure 13).
5. Carrier connector with retaining ring. 26. Shim.
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1-3
F7475
J 34011
Figure 4— Removing the Axle Tube Bearing and Seal Figure 5—Removing the Output Shaft Pilot Bearing
Figure 7— Separating the Carrier Case Halves Figure 10— Remove the Sleeve Bearing
J 33837-1
Figure 9— Removing the Side Bearing Cup Figure 12—Remove the Pinion Flange
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1-7
Tools Required:
J 2619 Slide Hammer
J 8614-01 Pinion Flange Remover
J 21551 Bearing Remover
J 22912-01 Pinion Bearing Cone Remover
J 29307 Slide Hammer
J 33791 Bushing Remover
J 33792 Side Bearing Adjuster Wrench
J 33837 Pinion Bearing Cup Remover Kit
J 29369-2 Countershaft Roller Bearing Remover
1. Shaft with deflector and retaining ring.
• Strike the inside of the shaft flange with a
soft-faced hammer to dislodge the shaft. Use
care in pulling the splined shaft through the seal
diameter to avoid cutting the seal.
2. Bolts.
4C1-8 7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE
Important
$ Tighten
PINION INSTALLATION
+«- Install or Connect (Figure 1 through 3, 11, 23,
24 and 25)
J 33785
Tools Required:
J 33785 Bearing Installer
J 8614-01 Pinion Flange Remover
J 33782 Seal Installer
1. Shim to the pinion gear.
• The shim must be of the proper size, as select
ed previously.
2. Bearing onto the pinion gear using J 33785 (figure
23).
3. New spacer onto the pinion gear.
4. Bearing into the case.
5. Seal into the case using J 33782 (figure 24).
6. Pinion gear, with bearing and spacer, to the case. Figure 23— Installing the Pinion Bearing
7. Deflector, flange, washer and nut.
A. Apply PST sealant (GM P/N 1052080) or equiv
alent to the pinion gear threads and on both
sides of the washer.
B. Tighten nut until no end play is detectable while
holding the flange with J 8614-01 (figure 11).
C. No further tightening should be attempted until
bearing preload has been checked.
Measure
DIFFERENTIAL ASSEMBLY
INSTALLATION
Install or Connect (Figures 1 through 3, 26
and 27)
Tools Required:
J 33788 Bearing Installer
J 23423-A Bearing Cup Installer
J 33792 Side Bearing Adjuster Wrench
1. Bearings into the sleeves using J 33788 (figure
26).
2. Sleeves into the carrier case. Thread in all the way.
3. Side bearing cups into the carrier case using
J 23423-A.
4. Differential assembly to the carrier case.
A. Place the differential case assembly into the
carrier case half which contains the pinion gear.
B. Turn the left sleeve in toward the differential
case using J 33792 until backlash is felt
between the ring and pinion gear.
5. Carrier case halves. Do not use any sealer at this
time.
• If the carrier halves do not make complete con
tact, back out the right hand adjusting sleeve.
Use J 33792 (figure 27).
6. Four bolts.
Tighten
ADJUSTING BACKLASH
Tools Required: (Figures 27 through 30)
J 33792 Side Bearing Adjuster Wrench
J 8001-1 Dial Indicator Clamp
1. Tighten the right sleeve to 140 N m (103 lbs. ft.)
using J 33792 (figure 27).
2. Tighten the left sleeve to 140 N-m (103 lbs. ft.)
using J 33792 (figure 27).
3. Mark the location of the adjusting sleeves in rela 1
tion to the carrier halves, indicated by the number
(1) (figure 28), so the notches in the adjusting
sleeves can be counted when turned.
4. Turn the right adjusting sleeve OUT two notches
using J 33792.
5. Turn the left adjusting sleeve IN one notch using
J 33792.
6. Rotate the pinion several times to seat the bear
ings.
7. Install J 34047, J 25025-1 and J 8001-1 (AWD
Only) (figure 29).
8. Place the indicator stem at the heel end of a tooth
(AWD Only).
9. Install a dial indicator so the button contacts the
outer edge of the pinion flange. The plunger must
be at a right angle to the pinion flange (figure 30).
10. Move the pinion flange through its free play while
holding the differential carrier. Record the dial indi
cator reading. Figure 28—Marking Sleeve Location
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1-13
TEST
1. Wipe oil out of axle housing and carefully clean
each tooth of the ring gear.
2. Apply gear marking compound sparingly to all
ring gear teeth using a medium stiff brush.
Flange
Important
FINAL ASSEMBLY
PART-TIME FRONT DRIVE AXLE
Figure 33— Gear Tooth Contact Pattern Is Correct
«-+ Remove or Disconnect (Figures 1 and 3)
Tools Required:
J 33844 Bearing Installer
J 33893 Axle Seal Installer
J 33799 Shift Housing Seal Installer
J 33842 Differential Pilot Bearing Installer
J 33791 Case Bushing Installer
1. Apply a bead of sealer (GM P/N 1052357) or
Figure 34—Pinion Gear is too Close to Ring Gear equivalent) to one carrier case surface.
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1-15
£ Tighten
$ Tighten
Clean
Figure 36— Installing the Shift Housing Seal
• All oil and grease from the cover and carrier
sealing surfaces. Use carburetor cleaner or
equivalent.
• Apply sealer (GM P/N 1052357) or equivalent)
to the cover.
6. Cover and bolts.
Tighten
Figure 35— Installing the Shaft Seal Figure 38— Installing the Thrust Washer
4C1-16 7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE
$ Tighten
Tool Required:
J 33799 Engagement Tool
• Operation of the shift mechanism. Insert J 33799
into the shift fork (figure 39). Turn the axle shaft
while engaging and disengaging the shift mecha
nism with the tool. The mechanism should operate
smoothly. If not, remove the tube and check for
damaged or improperly installed parts.
ALL WHEEL DRIVE (AWD) FRONT AXLE
JQi Clean
+ 4- & Tighten
Install or Connect (Figures 2, 3, 16, 17 and 35)
F6721
Figure 42— Removing Outer Deflector Ring Figure 45—Separating C/V Joint and Axle
Figure 44— Installing Outer Deflector Ring Figure 47—Installing Seal Retaining Clamp
4C1 -20 7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE
Figure 49—Swage Ring in Proper Alignment Figure 51—Separating Outer Race and Cage
4. Repeat this process until all six balls are removed.
Important 5. Position (1) cage and inner race 90 degrees to
centerline of outer race and align cage windows
•M ak e sure that seal, (1) housing and (2) with (2) lands of outer race (figure 51).
swage ring all remain in alignment. 6. Cage and inner race from outer race.
E. Continue to tighten each bolt 180 degrees at a 7. Rotate (3) inner race 90 degrees to center line of
time, alternating until both sides are bottomed. cage with (1) lands of inner race aligned with (2)
windows ofcage (figure 52).
9. Remove axle assembly from tool. 8. Pivot inner race into cage window and remove
inner race.
OUTER JO IN T ASSEMBLY
* Assemble (Figures 41, 51 and 52)
* Disassemble (Figures 41, 50, and 51)
• Apply chassis grease to the ball grooves of the
1. Remove outer joint seal. Refer to “OUTER JOINT inner race, and outer race.
SEAL.”
1. Inner race to the cage (figure 52).
2. Use a brass drift and hammer to gently tap on C/V
joint cage until it is tilted enough to remove first A. Rotate cage with inner race to the outer race
chrome alloy ball (figure 50). (figure 51).
3. Tilt cage in opposite direction to remove opposing B. Align the cage windows (2) with the lands (1).
ball. Pivot the cage into position (figure 51).
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1-21
Figure 52—Separating Inner Race and Cage Figure 53—Removing Spider Assembly
Important
Important
V Important
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener N-m Lbs. Ft. Lbs. In.
Adjusting Sleeve Lock Bolts................................................................................. 8.0 — 71
Carrier Case Bolts.................................................................................................. 47 35 —
Differential Ring Gear Bolts.................................................................................. 80 60 —
Left Hand Output Shaft Cover Bolts................................................................... 25 18 —
Tube Attaching Bolts................................................................ ............................. 48 35 —
LUBRICATION
Capacity........... .....................................................................................................................1.2 Liters (2.6 Pints)
Type................. ...........................................................................................SAE 80-W-90 GL-5 Gear Lubricant
T2378
4C1-24 7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE
SPECIAL TOOLS
1. J 21551 12 . J 8614-01
4. J 33785
15. J 29369-2
5. J 33788
16. J 29307
J 33790
17. J 33791
7. J 33792
18. J 8001
8. J 22912-01
3® J 25025-1
9. J 23423-A
J 36652
10.
F7518
8 1/4 AND 9 1/4-INCH RING GEAR 4C2-1
SECTION 4C2
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................4C2- 2
Disassembly of the Axle......................................................................................................................................... 4C2- 2
Inspection................................................................................................................................................................4C2- 2
Disassembly........................................................................................................................................................... 4C2- 2
Cleaning...................................................................................................................................................................4C2- 4
Inspection............................................................................................................................................................... 4C2- 5
Axle Housing......................................................................................................................................................4C2- 5
Differential........................................................................................................................................................... 4C2- 5
Pinion and Ring Gear....................................................................................................................................... 4C2- 5
Bearings.............................................................................................................................................................. 4C2- 6
Shims, Thrust Washers, and Adjuster Sleeves......................................................................................... 4C2- 6
Shift Mechanism................................................................................................................................................ 4C2- 7
Actuator Check...................................................................................................................................................4C2- 7
Assembly of the Axle.............................................................................................................................................. 4C2- 8
Pinion Bearing Cup Installation........................................................................................................................4C2- 8
Pinion Depth Adjustment....................................................................................................................................4C2- 9
Pinion Installation..................................................................................................................................................4C2-10
Differential Case Assembly................................................................................................................................ 4C2-11
Differential Assembly Installation......................................................................................................................4C2-11
Adjusting Backlash................................................................................................................................................4C2-13
Measuring Backlash......................................................................................................................................... 4C2-13
Gear Tooth Contact Pattern Check...................................................................................................................4C2-13
Gear Tooth Term s............................................................................................................................................. 4C2-13
Test................................................................. ...................................................................................................... 4C2-13
Adjustments Affecting Tooth Contact.......................................................................................................... 4C2-13
Carrier Case Assembly..................................... .................................................................................................. 4C2-14
Axle Tube Assembly............................................................................................................................................4C2-15
Assembly............................................................................................................................................................. 4C2-15
Output Shaft Shim Selection.......................................................................................................................... 4C2-15
Final Assembly......................................................................................................................................................4C2-17
Drive Axle Assembly................................................................................................................... •..........................4C2-17
Outer Deflector Ring Replacement............................................................................. ......................... ........... 4C2-17
ABS Sensor Ring Replacement.........................................................................................................................4C2-17
Outer Joint Seal Replacement........................................................................................................................... 4C2-18
Outer Joint Assembly Replacement................................................................................................................ 4C2-20
Inner Tripot Seal Replacement.......................................................................................................................... 4C2-21
Specifications............................................................................................................................................................ 4C2-23
Fastener Tightening Specifications...................................................................................................................4C2-23
Available Shim Sizes............................................................................................................................................ 4C2-23
Pinion Preload and Backlash............................................................................................................................4C2-23
Lubrication.............................................................................................................................................................. 4C2-23
Special Tools................ ........................................................................................................... ........ ........................ 4C2-24
4C2-2 8 1/4 AND 9 1/4-INCH RING GEAR
GENERAL DESCRIPTION
The front axle used on T model (RPO ZR2) and K transmit the driving force. This prevents tire scuffing
model vehicles has a center disconnect feature that, when going around corners and prevents premature
under most conditions, allows shifting into and out of wear on internal axle parts.
four-wheel drive when the vehicle is in motion. The axle The differential case is supported in the axle housing
is shifted by a thermal actuator. by two tapered roller bearings. The differential and ring
The axle uses a conventional ring and pinion gear set gear are located in relationship to the pinion by using
to transmit the driving force of the engines to the threaded adjusters.
wheels. The pinion gear is supported by two tapered The axle identification is an alphabetic broadcast
roller bearings. The pinion depth is set by a shim locat code located on a tag attached to the right axle tube.
ed between the gear end of the pinion and the roller The axle is produced with 8 1/4-inch and 9 1/4-inch
bearing that is pressed onto the pinion. The pinion ring gears. The 8 1/4-inch ring gear is used on T mod
bearing preload is set by crushing a collapsible spacer els (RPO ZR2), K1 and K2 models; the 9 1/4-inch ring
between the pinion bearings in the axle housing. gear is used on K3 models.
The ring gear is bolted onto the differential case with The drive axles are completely flexible assemblies
left-hand thread bolts. consisting of inner and outer constant velocity (CV)
The differential is used to allow the wheels to turn at joints protected by thermoplastic boots and connected
different rates of speed while the front axle continues to by an axle shaft.
DISASSEMBLY OF AXLE
INSPECTION 1. Differential actuator.
2. Engagement switch.
Perform the following checks before disassembling 3. Bolts.
the axle. 4. Axle tube with right output shaft.
5. Differential sleeve.
1. Remove the drain plug from the axle and drain the
6. Shift shaft, damper spring, shift fork, and shifter
axle lubricant.
shaft ring.
2. Check the ring gear backlash. Refer to “AJUSTING
7. Spring.
BACKLASH.” This information can be used to
8. Shim.
determine the cause of the axle problem. It will
9. Carrier connector with retainer ring (T, K1 and K2
also help when setting up the shim packs for locat
models).
ing and preloading the differential case.
3. Inspect the case for metal chips. Determine where • Clamp the axle tube in a vise. Clamp only on
the metal chips came from, such as a broken gear the mounting flange.
or bearing cage. • Strike the inside of the shaft flange with a brass
4. Determine the cause of the axle problem before hammer to dislodge the carrier connector.
disassembly if possible.
10. Snap ring and washer and thrust washer (K3 mod
els) (figure 8).
DISASSEMBLY
Remove or Disconnect (Figures 1 through 19)
Tools Required:
J 29369-1 Bearing Remover (T, K1 and K2 Mod
els)
J 29369-2 Bearing Remover (K3 Models)
J 29307 Slide Hammer
J 34011 Pilot Bearing Remover
J 36599 Adjusting Sleeve Wrench
J 36615 Adjuster Plug Wrench (K3 Models)
J 8614-01 Pinion Remover
J 36598 Holding Fixture and Pinion Service Tool
J8612-B Pinion Bearing Remover (T, K1 and
K2 Models)
J 36606 Pinion Bearing Remover (K3 Models)
J 22888 Side Bearing Puller
J 8107-2 Side Bearing Puller Pilot (T, K1 and K2
Models)
J 36597 Side Bearing Puller Pilot (K3 Models)
J 36616 Bushing Replacer
8 1/4 AND 9 1/4-INCH RING GEAR 4C2-3
11. Right output shaft with deflector. 23. Adjuster plug with side bearing cup and O-ring seal
12. Seal and output shaft bearing. Use J 29369-1 (T, (K3 models). Use J 36615 (figure 15).
K1, and K2 models) or J 29369-2 (K3 models) with 24. Nut. Use J 8614-01 to hold the pinion flange (figure
J 29307 (figure 12). 16).
13. Output shaft. 25. Washer.
14. Differential pilot bearing. Use J 34011 (figure 12). 26. Pinion flange with deflector. Use J 8614-01 (figure
15. The left output shaft with deflector using tool 16).
J 2619-1 (figure 13). • Mount the left carrier case in J 36598. Be sure to
16. Seal. Pry out with seal removal tool. use the adapter plate (J 36598-6) for T, K1 and K2
17. Bearings. Use the tools listed in step 12. models.
18. Bolts.
27. Ring and pinion with shim, bearing cone, and spac
19. Right side carrier half. Tap on the cast lugs provid
er. Use J 36598 (figure 17).
ed.
28. Spacer from the pinion.
20. Differential assembly.
29. Pinion bearing. Use J 8612-B (T, K1 and K2 mod
• Pry up on the locks (right side only on K3). els) or J 36606 (K3 models) and a press (figure
21. Bolt and lock (K3 models) (figure 15). 18).
22. Sleeve(s) and side bearing cups (right side only on 30. Shim.
K3). 31. Seai, and bearing cup and cone, Use J 36598-6
• Turn the sleeve(s) to push the bearing cup(s) (figure 19).
out of the bore(s). Use J 36599 (figure 14). 32. Bearing cup. Use J 36598-6 (figure 20).
4C2-4 8 1/4 AND 9 1/4-INCH RING GEAR
Figure 7—Right Case Half Figure 9—Left Output Shaft (K3 Models)
33. Side bearings. Use J 22888-D and J 8107-2 (T, K1 B. Remove the side gears and the side gear thrust
and K2 models) or J 36597 (K3 models) (figure washers. Mark the gears and the differential
21).
case as left and right.
34. Ring gear bolts.
C. Remove spacer (K3 models only).
• Ring gear bolts have left-handed threads.
40. Vent plug. Use a 6-point deep socket.
NOTICE: Do not pry the ring gear from the 41. Bushings. Use J 36616 (figure 23 and 24).
case. This will damage the ring gear and the
differential case. CLEANING
• Do not steam-clean drive parts having ground and
35. Ring gear from the differential case.
polished surfaces such as gears, bearings, and
• Drive the ring gear off with a brass drift. shafts. All parts should be disassembled before
36. Pin (T, K1 and K2 models). Drive out with a drift cleaning. These parts should be cleaned in a suit
and hammer (figure 22). able solvent.
37. Bolt (K3 models). • Parts should be thoroughly dried immediately after
38. Shaft. cleaning. Use soft, clean, lintless rags. Parts may
39. Differential pinion gears and side gears. be dried with compressed air. Do not allow the
A. Roll the pinion gears out of the case with the bearings to spin while drying them with com
pinion thrust washers. pressed air.
8 1/4 AND 9 1/4-INCH RING GEAR 4C2-5
J 34011
Figure 10— Removing the Snap Ring (K3 Models) Figure 12—Removing the Pilot Bearing
J 23907
J 2 93 69 -2
J 29369-1
Figure 11—Removing the Axle Bearing Figure 13— Removing the Left Shaft
DIFFERENTIAL
INSPECTION
It is very important to carefully and thoroughly inspect I? Inspect
all drive unit parts before assembly.
Thorough inspection of the parts for wear or stress • Pinion gear shaft for unusual wear.
and replacement of worn parts will help prevent costly
• Pinion gear and side gear teeth for wear, cracks,
drive component repair after reassembly.
scoring, and spalling.
AXLE HOUSING • Thrust washers for wear.
• The fit of the differential side gears in the differen
I9 Inspect tial case.
• The fit of the side gears on the axle shafts.
• Axle housing bore for nicks or burrs that would • Differential case for cracks and scoring.
prevent the outer diameter of the pinion seal from • All parts for wear and replace if necessary.
sealing. Remove any burrs that are found.
• Bearing cup surfaces for nicks or burrs. Remove PINION AND RING GEAR
any burrs that are found.
• Housing for cracks. Replace the housing if any • Ring and pinion gears are matched sets and must
cracks are found. both be replaced any time a replacement of either
• Housing for foreign material such as metal chips, is necessary.
dirt, or rust. Refer to “CLEANING.”
4C2-6 8 1/4 AND 9 1/4-INCH RING GEAR
Figure 15—Turning the Adjuster Plug (K3 Models) Figure 17—Removing the Pinion
L* Inspect
Important
• Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear. • When replacing worn or cracked bearings and
• Pinion gear splines for wear. cups, make sure to replace bearings in sets.
• Pinion flange splines for wear. • Low mileage bearings may have very small
• The fit of the pinion flange on the pinion gear. scratches and pits on the rollers and the bearing
• Sealing surface of the pinion flange for nicks, burrs, cups from the initial preload. Do not replace a
or rough tool marks which would cause damage to bearing for this reason.
the inside diameter of the pinion seal and result in
an oil leak. SHIMS, THRUST WASHERS, AND ADJUSTER
• All parts for wear and replace if necessary. SLEEVES
BEARINGS
I? Inspect
L* Inspect
• Shims and thrust washers for cracks and chips.
Bearings for smooth rotation after oiling them. Damaged shims should be replaced with an equal
Bearing rollers for wear. ly sized service shim.
Bearing cups for wear, cracks, brinelling and scor • Adjuster sleeves for damaged threads. Replace if
ing. required.
8 1/4 AND 9 1/4-INCH RING GEAR 4C2-7
Figure 19— Removing the Outer Pinion Bearing and Figure 21— Removing the Side Bearings
Seal
ACTUATOR CHECK
SHIFT MECHANISM • Apply 12-volt battery voltage to the actuator termi
nals. The plunger should extend within several sec
I? Inspect onds.
• Disconnect the actuator from the power source.
• Carrier connector (if used) for damaged splines The plunger should retract within several seconds.
and teeth. Replace as required. • If the actuator does not operate as specified, it
• Shift fork for wear, scoring, and damage to thrust should be replaced.
surfaces. Replace if needed.
• Differential sleeve and inner output shaft for dam
aged splines and teeth. Replace if necessary.
• Damper spring for breakage.
• Differential actuator and engagement switch for
damage and frayed wiring.
4C2-8 8 1/4 AND 9 1/4-INCH RING GEAR
J 36616
Figure 22—Removing the Pin (K1, 2 Models) Figure 24— Installing the Carrier Bushings
J 36616
Figure 25— installing the Outer Pinion Bearing Cup Figure 27—Measuring Pinion Depth-Button Located
in Bearing Bore
• Pull the bearing cup into place with the forcing 6. Insert the threaded rod of J 36601 through the pin
screw (figure 26). ion bearings.
7. Install the proper pilot, washer, and nut.
PINION DEPTH ADJUSTMENT 8. Tighten the nut while holding the threaded rod with
a wrench to adjust bearing preload. Adjust the nut
Tools Required:
to obtain a preload of 1.0-1.6 N-m (10-15 lbs. in.)
J 36601 Pinion Depth Setting Gauge
using an inch pound torque wrench. Rotate the
J 29763 Dial Indicator
shaft several times to make sure the bearings have
J 21777 Pinion Setting Gauge Set
seated, then measure again.
1. Refer to (figures 1 through 9, 27, 28 and 29). 9. Push the dial indicator downward until the needle
2. Pinion depth is adjusted by selecting a shim of the rotates about 3/4 turns.
proper thickness. 10. Tighten the dial indicator in this position.
3. Lubricate the pinion bearings liberally with axle 11. Set the button of J 36601 on the differential bear
lubricant. ing bore (figure 27).
4. Assemble J 29763 to the proper gaging arm 12. Rotate the tool slowly back and forth until the dial
(J 36601-4 for T, K1 and K2 models, J 36601-3 for indicator reads the lowest point of the bore. Set the
K3 models). dial indicator to ZERO. Repeat the rocking action
5. Install the pinion bearings and hold them in place. of the tool to verify the ZERO setting.
4C2-10 8 1/4 AND 9 1/4-INCH RING GEAR
J 3 6 6 0 1 -4
J 3 6 6 0 1 -3
Important
Tighten
DIFFERENTIAL ASSEMBLY
INSTALLATION
Install or Connect (Figures 1 through 9 and 34
through 38)
Tools Required:
J 36612 Bearing Installer (T, K1 and K2 Models)
Tools Required:
J 22761 Side Bearing Installer (T, K1 and K2
Models)
J 29710 Side Bearing Installer (K3 Models)
J 8092 Driver Handle
4C2-12 8 1/4 AND 9 1/4-INCH RING GEAR
J 36603
Figure 35—Turning the Adjuster Sleeve Figure 37— Installing the Side Bearing Cups
J 36613 Bearing Installer (K3 Models) • Turn the left sleeve (T, K1 and K2 models) or
J 8092 Driver Handle adjuster plug (K3 models) in until backlash is
J 36599 Sleeve Adjusting Wrench felt between the ring and pinion.
J 36615 Adjuster Plug Wrench (K3 Models)
J 36603 Side Bearing Cup Installer • T, K1 and K2 models: Use J 36599 (figure
1. Bearings to the sleeves and/or adjuster plug (K3 35).
models). • K3 models: Use J 36615 (figure 36).
• Use J 8092 and J 36612 (T, K1 and K2 models) • Remove the carrier case from J 36599.
or J 36613 (K3 models) (figure 34).
2. New O-ring seal to the adjuster plug (K3 models). 6. Carrier case halves. Do not use sealer at this time.
3. Sleeves and/or adjuster plug to the carrier case. • If the carrier halves do not make complete con
• T, K1 and K2 models: Use J 36599 (figure 35). tact, back out the right sleeve. Use J 36599
• K3 models: Use J 36599 for the right sleeve (figure 35).
(figure 35). Use J 36615 for the adjuster plug
(figure 36). 7. Bolts.
4. Side bearing cups. Use J 36603 with J 8092 (figure
37). Tighten
5. Differential assembly to the carrier case half.
• Place the differential assembly into the carrier • Bolts to 47 N-m (35 lbs. ft.).
case half which contains the pinion gear.
Figure 40— Pinion Gear is too Far Away Figure 42— Pinion Gear is too Close to Ring Gear
Figure 41—Gear Tooth Contact Pattern Is Correct Figure 43— Installing the Pilot Bearing
er to the centerline of the ring gear. Decreasing the Remove or Disconnect (Figures 1 through 9)
shim thickness will move the pinion farther away from
the centerline of the ring gear. 1. Bolts.
Backlash is adjusted by means of the side bearing 2. Right carrier case half.
adjusting sleeves which move the entire case and ring
gear assembly closer to, or farther from the drive pin
Clean
ion. (The adjusting sleeves are also used to set side
bearing preload). To increase backlash turn the left
sleeve in and turn the right sleeve out an identical • Carrier case and axle tube sealing surfaces.
amount. To decrease backlash, turn the right sleeve in Remove all grease and oil.
and turn the left sleeve out an identical amount.
It is important that the contact pattern be centrally + «- Install or Connect (Figures 1 through 9, 23,
located up and down on the face of the ring gear teeth. 24, and 43)
CARRIER CASE ASSEMBLY
-►«- Install or Connect (Figures 1 through 9) Tools Required:
J 36600 Output Shaft Seal Installer (K1, 2)
Bend the lock over the sleeves. (Right side only on J 22833 Output-Shaft Seal Installer (K3).
K3 models). J 33842 Pilot Bearing Installer
Bolt and lock (K3 models). J 36616 Bushing Replacer Set
8 1/4 AND 9 1/4-INCH RING GEAR 4C 2-15
Tighten
Tools Required:
J 36609 Bearing Installer
J 36600 Seal Installer (T, K1 and K2 Models)
J 22833 Seal Installer (K3 Models)
1. Bearing. Use J 36609. Drive into place with a ham
mer.
2. Seal. Use J 36600 (T, K1 and K2 models) or
J 22833 (K3 models) (figure 44).
3. Shaft with deflector to the axle tube.
4. Washer. Align the tabs with the slots in the tube.
5. Gear with retaining ring (T, K1 and K2 models).
Drive gear into place with a plastic hammer.
6. Washer and new snap ring (K3 models). Make sure
the snap ring seats properly in the groove.
Size-Carrier Case
Preferred Method:
Tool Required:
J 34672 Depth Gage (or equivalent)
• Refer to figures 45 through 48
4C2-16 8 1/4 AND 9 1/4-INCH RING GEAR
J 34672
Figure 47—Measuring to Calculate Shim Figure 49—Measuring Axle Shaft End Play
Size-Dimension "A"
• If the figure obtained in step 5 was 3.30 mm,
use a 2.70-mm shim (T, K1 and K2 models) or
2.80-mm shim (K3 models).
6. Shims are available in the following sizes:
• T, K1 and K2 models: 1.27 mm 1.78 mm, 2.29
mm, 2.70-mm, 3.30 mm, 3.81 mm.
• K3 models: 1.80 mm, 2.30 mm, 2.80 mm, 3.30
mm, 3.80 mm, 4.30 mm, 4.80 mm.
Alternate Method
Use only if proper tools for calculating the shim size
are not available.
1. Bolts.
2. Axle tube assembly.
FINAL ASSEMBLY
jjj| Clean (Figures 1 through 9)
Shift mechanism operation. Insert a drift into the • Actuator bolts to 22 N-m (16 lbs. ft.)
actuator hole in the axle tube. Rotate the axle • Switch bolts to 5 N-m (45 lbs. in.)
flange while moving the shift fork with the drift. • Drain and fill plug to 33 N-m (24 lbs. ft.)
The shift mechanism should work smoothly,
without binding.
“►4- Install or Connect 1. Light film of oil onto the inside of the sensor ring.
• Ring must face with chamfer side up.
Position and square up the deflector ring at the 2. Sensor ring with J 39245.
press diameter of C/V outer race. • On T, K1 and K2 models use both the large
Using a (1) 3-inch pipe coupling (T, K1 and K2) fixture and smaller spacer.
or 4-inch pipe coupling (K3), a (2) fabricated • On K3 models use only the larger fixture.
sheet metal sleeve, and a (3) M24 x 2.0 nut, as 3. Deflector ring.
shown in (figure 52), tighten nut until deflector
A. Position and square up the deflector ring at the
bottoms against shoulder of C/V outer race.
press diameter of the outer race.
4C2-18 8 1/4 AND 9 1/4-INCH RING GEAR
OUTER JO IN T SEAL
REPLACEMENT
Remove or Disconnect (Figures 54)
Tools Required:
J 8059 Snap Ring Pliers
J 35910 Seal Clamp Tool
J 36652 Swage Clamp Tool
1. Large swage ring from the C/V joint, using a chisel
and discard.
Important
A. Slide the seal onto the axle shaft and position Important
the neck of the seal in the seal groove on the
axle shaft.
• The seal must not be dimpled, stretched or
B. Crimp the self retaining clamp with J 35910 to
out of shape in any way. If the seal is not
136 N-m (100 lbs. ft.) (figure 56).
shaped correctly, carefully insert a thin flat
C. Place approximately half of the grease provided
blunt tool (no sharp edges) between the
inside the seal and repack the C/V with the
large seal opening and the outer race at
remaining grease.
maximum clearance of oval ring to release
2. Swage ring. the air. Shape the seal by hand and remove
the tool.
A. Pinch by hand slightly to distort into an oval
shape and slide onto large diameter of the seal. D. Select the correct size swage clamp tool
B. Push C/V joint onto axle shaft until retaining J 36652
ring is seated in groove on axle shaft (figure
55).
4C2-20 8 1/4 AND 9 1/4-INCH RING GEAR
Important
Balls.
A. Tap on the cage with a brass drift to tilt it
enough to install the balls (figure 59).
B. Pack the joint with chassis grease.
Important
Tools Required:
J 8059 Snap Ring Pliers Figure 63—Installing Spider Assembly
J 35910 Seal Clamp Tool
J 36652 Swage Clamp Tool
1. Large swage ring from the in-pot joint, using a chis
el, and discard.
Important
Important
Important
Important * Be sure that the counterbored A. Position the inboard end of the axle assembly
in the tool.
face of the tripot spider faces the end of
B. Place the top half of the proper size tool on the
the shaft. lower half of tool and check for proper align
ment and dimension (figures 57, 58 and 65).
C. Insert the bolts and tighten by hand until snug.
4. Shaft retaining ring in the groove of the axle shaft
with J 8059.
Important
5. Slide the tripot spider towards the end of the shaft
and reseat the spacer ring in the groove on the
axle (figure 63). • Make sure that the seal, housing and swage
ring all remain in alignment (figure 57 and
A. Place approximately half of the grease provided 58).
in the seal and use the remainder to repack the
tripot housing. D. Continue to tighten each bolt 180 degrees at a
time, alternating until both sides are bottomed.
6. Pinch the swage ring by hand slightly to distort it
into an oval shape and slide it onto the large diam 12. Remove the axle assembly from the tool.
eter of the seal.
8 1/4 AND 9 1/4-INCH RING GEAR 4C 2-23
SPECIFICATIONS
FASTENER TIG HTENING SPECIFICATIONS
Fastener N-m Lbs. Ft. Lbs. In.
Actuator................................................................................... ......................................... 22 16 —
Axle Tube Bolts............................................................ ......................................... 40 30 —
Carrier Case Bolts........................................................ ......................................... 47 35 —
Drain and Fill Plugs..................................................... ......................................... 33 24 —
Front Axle Switch......................................................... ......................................... 5.0 — 45
Ring Gear Bolts............................................................ ......................................... 120 88 —
Seal Retaining Clamp....................................................... .............................................. 136 100 —
LUBRICATION
Capacity Liters Pints
8 1/4-Inch Ring Gear................................................................................................................. 2.0 4.5
9 1/4-Inch Ring Gear................................................................................................................. 2.8 6.0
Type.............................................................................................................................. SAE 80-W-90 GL-5 Gear Lubricant
T2518
4C2-24 8 1/4 AND 9 1/4-INCH RING GEAR
SPECIAL TOOLS
J 29307 10 J 36616
J 36612 11 J 22761
J 36613 12 J 29710
13 J 22888
J 8092
J 8107-2 14 J 36609
J 36597
15 J 29369-1
J3612-B 16 J 29369-2
J 36606
17 J 33842
J 8614-01
18 J 34011
1. Slide Hammer
2. Output Shaft Bearing Installer (K15-25)
3. Output Shaft Bearing Installer (K35)
4. Driver Handle
5. Side Bearing Puller Pilot (K15-25)
6. Side Bearing Puller Pilot (K35)
7. Pinion Bearing Remover (K15-25 Models)
8. Pinion Bearing Remover (K35 Models)
9. Pinion Flange Remover
10. Case Bushing Replacer
11. Differential Side Bearing Installer
(K15-25 Models)
12. Differential Side Bearing Installer
(K35 Models)
13. Differential Side Bearing Puller
14 Axle Tube Bearing Installer
15. Axle Tube Bearing and Seal Remover
(K15-25 Models)
16. Axle Tube Bearing and Seal Remover
(K35 Models)
17. Differential Pilot Bearing Installer
18. Differential Pilot Bearing Remover
F6761
8 1/4 AND 9 1/4-INCH RING GEAR 4C2-25
SPECIAL TOOLS
19 J 35512 29 J 34037
20 J 36614
J 36366 30 J 34672
J 36600
J 22833
31 J 36615
J 36598
25 J 34047-3 32 8001
26 J-36599
27 J 36601
28 J 29763
35 J 35910
36 J 36603
b iW ©biS tC
(si$boM a S ^ fM ) m e a efxA- SS
|aw W ^lau'ibA gn
_
BRAKES 5-1
........ ■■■■—........ .......................................................... ■ ........... ............
SECTION 5
BRAKES
CONTENTS
SUBJECT
Master Cylinder Unit Repair..................................................................................................................................5A1-1
Vacuum Booster.......................................................................................................................................................5A2-1
Hydraulic Booster....................................................................................................................................................5A3-1
NOTES
Brmrwo
»***• •<
MASTER CYLINDER U N IT REPAIR 5A1-1
SECTION 5A1
NOTICE: Do not hone the master cylinder bore. When the brake master cylinder is overhauled, it is
recommended that the cylinder body be replaced rather than “cleaned up” by honing the bore. The
master cylinder has a hard, highly polished “bearingized” surface, which is produced by diamond boring
followed by ball or roller burnishing under heavy pressure. Honing will destroy this hard smooth surface
and cause rapid wear of the rubber cups.
NOTICE: Do not use unapproved solvents when cleaning or flushing the master cylinder and related
components. The use of these liquids as cleaning solvent will damage the rubber parts in the system if
they have any trace of mineral oil or other contaminants.
CONTENTS
SUBJECT PAGE
General Description....................................................................................................................................................5A1-1
Master Cylinders......................................................................................................................................................... 5A1-2
Composite Master Cylinder...................................................................................................................................5A1-2
Cast Iron Master Cylinder..................................................................................................................................... 5A1-3
Bendix Master Cylinder......................................................................................................................................... 5A1-5
Specifications.............................................................................................................................................................. 5A1-6
Fastener Tightening Specifications.....................................................................................................................5A1-6
GENERAL DESCRIPTION
Master cylinders have identifying information stamped Bendix master cylinders have the information stamp
into the unit. ed into the front surface of the body. The first digit
Delco chassis master cylinders (composite or cast indicates the plant where it was built. The second digit
iron) have identification information on the front surface digit shows the year it was built. (1 means 1991, a 2
of the body. The first and second digits are the build means 1992, etc.).The last digits show the day it was
code. The third digit shows the year it was built. (1 built (Example: 271 means it was the 271st day of the
means 1991, 2 means 1992, etc.). The last digits show production year).
the day it was built. (Example: 271 means it was the
271st day of the production year).
5A1-2 MASTER CYLINDER U N IT REPAIR
MASTER CYLINDERS
COMPOSITE MASTER CYLINDER
Remove or Disconnect (Figures 1 through 5)
1. Cover.
2. Diaphragm.
3. Brake fluid from reservoir.
4. Reservoir and grommets (figure 5).
• Clamp the mounting flange in a vise and pry
the reservoir off with a bar.
5. Snap ring.
6. Primary piston assembly.
MASTER CYLINDER U N IT REPAIR 5A1-3
7. Secondary piston.
• With the rear port plugged, apply a small
amount of air pressure to the front port.
8. Seals.
9. Spring retainer and spring.
Clean
IfU
Figure 7—Installing the Reservoir
• All metal parts in denatured alcohol.
• All rubber parts in clean brake fluid. 5. Snap ring.
• Stained or discolored cylinder bore with crocus
cloth. • The primary piston must be compressed when
installing the snap ring.
Inspect 6. Grommets.
7. Reservoir (figures 6 or 7).
• Diaphragm for cuts, cracks, or a swollen condition.
• Cylinder bore for scoring or corrosion. • Press on the body while using a rocking motion.
— If corrosion is present, replace the cylinder. 8. Diaphragm in cover.
— Do not attempt to hone the bore. 9. Cover.
• Reservoir for cracks.
Figure 6—Installing the Reservoir Figure 8—Cast Iron Master Cylinder Cover
5A1-4 MASTER CYLINDER U N IT REPAIR
Clean
J^ Inspect
6. Secondary piston.
1. Cover.
2. Diaphragm.
3. Drain brake fluid from reservoir.
4. Bolts and reservoir.
5. O-ring and compensating valve seals.
6. Valve poppets and springs.
7. Depress primary piston with a smooth rounded end
tool.
8. Snap ring.
9. Primary piston assembly and piston return spring.
Ijjp Clean
$ Tighten
Lubricate seals and cylinder bore with clean brake
fluid.
Bolts to 18 N-m (13 lbs. ft.).
1. Secondary spring.
10. Diaphragm in cover.
2. Secondary piston assembly.
11. Cover.
3. Piston return spring.
5A1-6 MASTER CYLINDER U N IT REPAIR
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Nm Ft. Lbs.
Bendix Reservoir Bolts................................................................................................................... 18 13
VACUUM BOOSTER 5P2-1
^ •• .. ■«*>
SECTION 5D2
■ '-'f ■ •- . ■ ,, j? .i; * ' •. v v ■■■ v ■ .# * ''1 '■ & * '• * * ; r1: ’ ">?*
f- . ■- J \' 4 ,# v 1 w‘ 'a i . I ?t fM
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. Fasteners that are not reused and those requiring thread locking compound will be called out.
The correct torque value must be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
SUBJECT PAGE
General Description....................................................................................................................................................5D2-1
Booster Assembly..................................................................................................................................................... 5D2-1
Single Diaphragm....................................................................................................................................................5D2-1
Dual Diaphragm.......................................................................................................................................................5D2-3
Gaging Procedure.......................................................................................................................................................5D2-6
Special T ools............................................................................................................................................................... 5D2-7
GENERAL DESCRIPTION
The vacuum booster is either a single or tandem dia Delco Moraine NDH vacuum boosters have a build
phragm vacuum suspended unit. During normal opera date on a small paper label glued to the front housing.
tion, with the brake pedal released, manifold vacuum is The first digit indicates the plant where it was built, and
applied to both sides of the diaphragm(s). Applying the the second digit indicates the year (1 means 1991, 2
brakes allows air at atmospheric pressure to enter one means 1992, etc.). The last digits indicate the day it
side of the diaphragm(s). This pressure difference pro was built (Example: 271 would mean the 271st day of
vides the power assist. the production year).
BOOSTER ASSEMBLY
SINGLE DIAPHRAGM
4-+ Remove or Disconnect (Figures 1 through 4)
Tool Required:
J 23456 Power Brake Booster Disassembly and
Reassembly Tool
1. Boot and silencer.
2. Vacuum check valve and grommet.
3. Front housing seal.
4. Scribe a mark across front and rear housings to aid
in reassembly.
5. Use J 23456 to apply force in a counterclockwise
direction to unlock housings (figure 1).
6. Return spring and power piston group.
7. Power piston bearing from rear housing.
8. Reaction body retainer.
9. Piston rod and reaction retainer.
10. Filter using an awl or similar tool.
11. Power piston and pushrod assembly.
A. Grasp outside edge of diaphragm support and
diaphragm. Figure 1—Unlocking and Locking the Booster
B. Hold pushrod down against a hard surface. Housing
5D2-2 VACUUM BOOSTER
Figure 2—Single Diaphragm Vacuum Booster Figure 4— Single Diaphragm Vacuum Booster Rear
Power Piston Housing
J 28458
Figure 3—Single Diaphragm Vacuum Booster Figure 5—Installing the Diaphragm Retainer
Diaphragm
Install or Connect (Figures 1 through 6)
C. Use a slight force or impact to dislodge dia
phragm retainer. Tools Required:
J 23456 Power Brake Booster Disassembly
12. Diaphragm from diaphragm support. and Reassembly Tool
L9
J 28458 Power Piston Seal Protector
Inspect
1. Diaphragm in diaphragm support.
All parts for corrosion, nicks, cracks, cuts, scoring, 2. Lubricate inside diameter of diaphragm lip with a
distortion, or excessive wear. Replace as needed. thin layer of Delco Silicone Lube (GM P/N
Use crocus cloth to polish away minor corrosion of 18010909) or equivalent.
the housings or diaphragm support. 3. Diaphragm and diaphragm support on power piston
and pushrod assembly.
| Clean 4. New diaphragm retainer (figure 5).
• Seat the retainer using J 28458.
All parts in clean denatured alcohol.
Do not immerse the power piston assembly in alco 5. Filter, reaction retainer, and piston rod.
hol. Wipe it clean with an alcohol dampened cloth. 6. Reaction body retainer.
Drv all parts with drv. unlubricated, comoressed air. 7. Power piston bearing in rear housing.
VACUUM BOOSTER 5D2-3
Figure 6—Staking the Housing Tabs Figure 7—Dual Diaphragm Vacuum Booster Rear
Housing
8. Lubricate inside and outside of bearing with Delco
Silicone Lube (GM P/N 18010909) or equivalent.
9. Power piston group in rear housing.
10. Return spring.
11. Front housing to rear housing.
A. Align marks made during disassembly.
B. Use J 23456 to apply force in a clockwise direc
tion to lock the front and rear housings.
C. Stake the housing at (1) two tabs 180 degrees
apart. (2) Unstaked tab, (3) Staking tab socket
(figure 6).
Figure 9— Dual Diaphragm Vacuum Booster Power Figure 11—Power Piston Group
Piston
19. Retaining ring from air valve pushrod assembly.
20. Air valve pushrod assembly by inserting a screw
driver through pushrod eyelet and pulling straight
out.
• Considerable force is required.
21. Filter, retainer, and O-ring from air valve pushrod
assembly.
L® Inspect
Clean
10. Power piston assembly along with the pushrod. -►4- Install or Connect (Figures 1 and 7 through
A. Grasp assembly at outside edge of housing 17)
divider and diaphragms.
Tools Required:
B. Hold assembly with pushrod down against a
J 23456 Power Brake Booster Disassembly
hard surface.
and Reassembly Tool
C. Use a slight force or impact to dislodge dia
J 29282 Air Valve Push Rod Retainer Installer
phragm retainer.
J 28458 Power Piston Seal Protector
11. Primary diaphragm and primary support plate from
housing divider.
12. Primary diaphragm from the primary support plate. 1. Lubricate O-ring with a thin layer of Delco Silicone
13. Secondary diaphragm and secondary support plate Lube (GM P/N 18010909) or equivalent and install
from housing divider. on air valve pushrod assembly.
14. Secondary piston bearing from housing divider. 2. Air valve pushrod assembly in power piston.
15. Secondary diaphragm from secondary support 3. New retainer and seat using J 29282 (figure 12).
plate. 4. Filter over pushrod eyelet and in power piston.
16. Reaction body from power piston. 5. Retaining ring on air valve pushrod assembly.
17. Reaction disc and reaction piston from reaction 6. Reaction bumper and air valve spring.
body. 7. Reaction piston and reaction disc in reaction body.
18. Air valve spring and reaction bumper from end of 8. Reaction body in power piston.
air valve pushrod. 9. Secondary diaphragm on secondary support plate.
VACUUM BOOSTER 5D2-5
Figure 12— Installing the Retainer in the Power Figure 14—Assembling the Housing Divider
Piston
Figure 16— installing the Diaphragm Retainer Figure 18—Gaging the Piston Rod
SPECIAL TOOLS
V3763
HYDRAULIC BOOSTER 5D3-1
SECTION 5D3
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. Fasteners that are not reused and those requiring thread locking compound will be called out.
The correct torque value must be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
SUBJECT PAGE
General Description....................................................................................................................................................5D3-1
Unit Repair....................................................................................................................................................................5D3-1
Booster Assembly...................................................................................................................................................5D3-1
Gaging Procedure....................................................................................................................................................5D3-4
Power Steering Pump............................................................................................................................................ 5D3-4
Specifications.............................................................................................................................................................. 5D3-5
Fastener Tightening Specifications.....................................................................................................................5D3-5
Special Tools............................................................................................................................................................... 5D3-5
GENERAL DESCRIPTION
The Bendix booster uses fluid pressure from the pow serves as the mounting surface for the master cylinder.
er steering pump to provide the power assist. The Identifying information is stamped into the housing
booster assembly is located on the left front cowl and near the inlet valve.
UNIT REPAIR
BOOSTER ASSEMBLY
CAUTION: The accumulator contains com
pressed gas. Always use the proper tools
and follow the recommended procedures or
personal injury may result. Do not apply heat
to accumulator. Do not attempt to repair an
inoperative accumulator. Always replace an
inoperative accumulator with a new one. Dis
pose of an inoperative accumulator by drill
ing a 1/16-inch diameter hole through the end
of the accumulator can opposite the O-ring.
Tool Required:
J 26889 Accumulator Piston Compressor
4. Retainer.
5. Release C-clamp.
6. Nut from stud.
7. Special tool J 26889.
8. Accumulator and O-ring seal.
9. Retainer (figure 5).
10. Plug and O-ring seal.
11. Spring.
12. Retainer.
13. Output pushrod and baffle.
14. Piston return spring and retainer.
• Saw eyelet off pedal rod.
15. Boot.
16. Nut and bracket.
17. Bolts.
18. Separate cover from housing.
19. Seals.
20. Piston assembly and seal.
21. Spool valve.
22. Accumulator valve.
• Make a wire hook, using following dimensions
3.0 mm (0.125-inch) 57 mm (2.25-inches), to
aid in the removal (figure 6).
23. Return line fitting and seal,
jg]* Clean
L1 Inspect
Tools Required:
J 26889 Accumulator Piston Compressor
J 24551-A Seal Protector
J 25083 Seal Protector
$ Tighten
a Tighten
SPECIFICATIONS
FASTENER TIG HTENING SPECIFICATIONS
N-m Ft. Lbs.
Hydraulic Booster Housing to Cover Bolts............................................ ................................... 30 22
Hydraulic Booster Nut.................................. ....................... ........... ......... .................................... 149 110
T2519
SPECIAL TOOLS
J 37839 J 25083
J 24551-A 4. J 26889
5. J 6217
NOTES
’■> : • I , .. . . .
ENGINE 6-1
' - .....
SECTION 6
ENGINE
CONTENTS
SUBJECT PAGE
General Engine Mechanical........................................................................................................................................ 6A-1
4.3L V6 Engine (VIN Z )............................................................................................................................................ 6A3B-1
4.3L V6 Engine (VIN W )........................................................................................................................................... 6A4B-1
V8 Engines.................................................................................................................................................................. 6A5B-1
6.5L Diesel Engine...................................................................................................................................................... 6A7-1
Engine Electrical........................................................................................................................................................... 6D-1
SD Starter M otors..................................................................................................................................................... 6D2A-1
28-MT Starter Motors............................................................................................................................................... 6D2B-1
CS-144 Generator...................................................................................................................................................... 6D3A-1
Distributors.................................................................................................................................................................. 6D4A-1
High Voltage Switch................................................................................................................................................6D4B1-1
6-2 ENGINE______________________________________________________
NOTES
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n v,> T -
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. -:.r ■ - ; £ :y~t*-y.w • ..
...........
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SECTION 6A
CONTENTS
SUBJECT PAGE
General Information.................................................................................................................................................... 6A- 2
Statement on Cleanliness and C are...................................................................................................................6A- 2
Use of RTV Sealer and Anaerobic Gasket Eliminator...................................................................................6A- 2
Using RTV Sealer.................................................................................................................................................6A- 2
Using Anaerobic Gasket Eliminator................................................................................................................6A- 2
Replacing Engine Gaskets.................................................................................................................................... 6A- 2
Cylinder Bores, Pistons, Rings, and Connecting R ods....................................................................................6A- 3
Measuring Cylinder Bore Taper and Out-of-Round (All Engines).............................................................. 6A- 3
Cylinder Bore Reconditioning (2.2L Engines)..................................................................................................6A- 3
Cylinder Bore Reconditioning (All Except 2.2L Engines)............................................................................. 6A- 4
Boring..........................................................................................................................................................................6A- 4
Honing............................. ...........................................................................................................................................6A- 4
Piston and Connecting Rod Assemblies.......................................................................................................... 6A- 5
Disassembly...........................................................................................................................................................6A- 5
Cleaning and Inspection.................................................................................................................................... 6A- 5
Measuring Piston Pin to Piston Clearance...................................................................................................6A- 6
Piston Selection (2.2L Engines).......................................................................................................................... 6A- 6
Piston Selection (All Except 2.2L Engines)...................................................................................................... 6A- 6
Assembly........................................................................................................... .................................................... 6A- 7
Camshaft Bearings...................................................................................................................................................... 6A- 9
Camshaft Bearing Replacement (2.2L Engines)............................................................................................ . 6A- 9
Camshaft Bearing Replacement (All Except 2.2L Engines)......................................................................... 6A- 9
Hydraulic Lifters.......................................................................................................................................................... 6A-10
Valve Lifter Leakdown Rate Test (Flat Type Lifters Only)............................................................................ 6A-10
Cylinder Head...............................................................................................................................................................6A-11
Disassembly...............................................................................................................................................................6A-11
Cleaning and Inspection........................................................................................................................................ 6A-11
Repair......................................................................................................................................................................... 6A-12
Valve Grinding...................................................................................................................................................... 6A-12
Valve Seat Grinding............................................................................................................................................ 6A-12
Reaming Valve Guides....................................................................................................................................... 6A-13
Assembly................................................................................................................................................................... 6A-13
Measuring Main Bearing Clearance........................................................................................................................6A-14
Measuring Connecting Rod Bearing Clearance........................................................................................... ....... 6A-15
Thread Repair...............................................................................................................................................................6A-17
Special Tools................................................................................................................................................................6A-18
6A-2 GENERAL ENGINE MECHANICAL
GENERAL INFORMATION
STATEMENT ON NOTICE: Attempting to pry or pull compo
nents apart may result in damage to the part.
CLEANLINESS AND CARE
3. Surfaces to be resealed must be clean and dry.
• An engine is a combination of many machined,
Remove all gasket material from the part using a
honed, polished, and lapped surfaces with very
plastic or wood scraper. Use Loctite brand “Chisel
close tolerances.
Gasket Remover” (P/N 79040), Permatex brand
• Whenever valve train, cylinder head, crankshaft, or
“Gasket Remover” (P/N 4MA) or equivalent. Follow
connecting rod components are removed for ser
all safety recommendations and directions that are
vice, they should be retained in order. At the time
on the can. Do not use any other method or tech
of installation, they should be installed in the same
nique to remove gasket material from a part. Do
locations and with the same mating surfaces as
not use abrasive pads, sand paper or power tools
when removed.
to clean gasket surfaces. These methods of clean
• Any time the air cleaner or TBI unit is removed, the
ing can damage the part. Abrasive pads also pro
intake opening must be covered. This will protect
duce a fine grit that the oil filter cannot remove
against the entrance of foreign material which
from the oil. This grit is abrasive and has been
could follow the intake passage into the cylinder
known to cause internal engine damage.
and cause extensive damage when the engine is
4. Apply RTV to one of the clean surfaces. Use a
started.
bead size as specified in the procedure. Run the
• When any internal engine parts are serviced, care
bead to the inside of any bolt holes. Do not allow
and cleanliness are important. Apply a liberal coat
the sealer in any blind threaded holes, as it may
ing of engine oil to friction areas during assembly
prevent the bolt from seating properly or cause
to protect and lubricate the surfaces during initial
damage when the bolt is tightened.
operation. Throughout this section, it should be
5. Assemble while RTV is still wet (within 3 minutes).
understood that proper cleaning and protection of
Do not wait for RTV to skin over.
machined surfaces and friction areas is part of the
6. Torque bolts to specifications. Do not overtighten.
repair procedure. This is considered standard shop
practice even if not specifically stated. USING ANAEROBIC GASKET ELIMINATOR
1. Surfaces to be resealed must be clean and dry.
USE OF RTV SEALER Remove all gasket material from the part using a
AND ANAEROBIC plastic or wood scraper. Use Loctite brand “Chisel
Gasket Remover” (P/N 79040), Permatex brand
GASKET ELIMINATOR “Gasket Remover” (P/N 4MA) or equivalent. Follow
Two types of sealer are commonly used in the all safety recommendations and directions that are
engines covered by this manual. These are RTV sealer on the can. Do not use any other method or tech
and anaerobic “gasket eliminator” sealer. nique to remove gasket material from a part. Do
It is important that these sealers be applied properly not use abrasive pads, sand paper or power tools
and in the proper place to prevent oil leaks. THE TWO to clean gasket surfaces. These methods of clean
TYPES OF SEALER ARE NOT INTERCHANGEABLE. ing can damage the part. Abrasive pads also pro
Use the sealer recommended in the procedure. duce a fine grit that the oil filter cannot remove
from the oil. This grit is abrasive and has been
• RTV (room temperature vulcanizing) sealer is used known to cause internal engine damage.
where a non-rigid part is assembled to a rigid part. 2. Apply a continuous bead of gasket eliminator to
Common examples are oil pans and rocker arm one flange.
covers. 3. Spread the bead evenly with your finger to get a
•A n aero b ic gasket eliminator hardens in the uniform coating on the complete flange.
absence of air. This sealer is used where two rigid 4. Assemble parts in the normal manner and torque
parts (such as castings) are assembled together. immediately to specifications.
When two rigid parts are disassembled and no
sealer or gasket is readily noticeable, the parts Important
were probably assembled using gasket eliminator.
Anaerobic sealed joints that are partially torqued
USING RTV SEALER
and allowed to cure more than five minutes may
1. Do not use RTV in areas where extreme tempera result in incorrect shimming of the joint.
tures are expected, such as exhaust manifold head
gasket, or where gasket eliminator is specified. REPLACING ENGINE GASKETS
2. When separating components sealed with RTV,
use a rubber mallet and “bump” the part sideways CAUTION: Composite type gaskets are used
to shear the RTV sealer. “Bumping” should be in some areas of the engine assembly. These
done at bends or reinforced areas to prevent dis gaskets have a thin metal core. Use caution
tortion of parts. RTV is weaker in shear (lateral) when removing or handling composite gas
strength than in tensile (vertical) strength. kets to help avoid personal injury.
GENERAL ENGINE MECHANICAL 6A-3
CYLINDER BORE
RECONDITIONING
(2.2L ENGINES)
1. Measure the cylinder bore for out of round and
taper as outlined previously.
2. Refer to (figure 2). Measure dimension “1” at 13
mm (1/2 inch) below the head gasket surface.
Measure dimension “2” at 100 mm (4 inches)
below the head gasket surface.
• Cylinder bores can be measured by setting the
cylinder gage dial at zero (in the cylinder) at the
point of desired measurement. Lock the dial
indicator at zero before removing it from the
cylinder, and measure across the gage contact
points with an outside micrometer, with the
gage at the same zero setting when removed
from the cylinder (figure 3).
3. If dimension “1” is larger than dimension “2” by
0.13 mm (0.005 inch), the cylinder should be bored
for oversized piston and rings.
• If relatively few bores require correction, it will
not be necessary to rebore all cylinders to the
same oversize in order to maintain engine bal
ance. All oversize service pistons are held to
the same weights as standard size pistons. Figure 2—Typical Wear Pattern
6A-4 GENERAL ENGINE MECHANICAL
BORING
1. Before the honing or reboring operation is started,
measure all new pistons with the micrometer con
tacting at points exactly 90 degrees from the piston
pin centerline. Some pistons must be measured at
a specified distance from the piston crown. Refer to
the proper section for additional instructions. Then
select the smallest piston for the first fitting. The
slight variation usually found between pistons in a
set may provide for correction in case the first pis
ton is fitted too loose.
2. Before using any type of boring bar, the top of the
cylinder block should be filed to remove any dirt or
burrs. This is very important. If not checked, the
boring bar may be tilted which would result in the
rebored cylinder wall not being at right angles to
the crankshaft.
3. The instructions furnished by the manufacturer of
the equipment being used should be carefully fol
lowed.
4. When reboring cylinders, all crankshaft bearing
CYLINDER BORE caps must be in place and tightened to the proper
RECONDITIONING (ALL EXCEPT torque to avoid distortion of bores in the final
2.2L ENGINES) assembly. Always make sure the crankshaft is out
of the way of the boring cutter when boring each
1. Measure the cylinder bore for out-of-round and cylinder. Crankshaft bearings and other internal
taper, as outlined previously.
parts must be covered or taped to protect them
2. Refer to figure 2. Measure for wear at the top of
during the boring or honing operation.
the bore (point “1”) and the bottom (point “2”).
5. When taking the final cut with a boring bar, leave
• Cylinder bores can be measured by setting the
0.03 mm (0.001 inch) on the diameter for finish
cylinder gage dial at zero in the cylinder at the
honing to give the required position to the cylinder
point of desired measurement. Lock the dial
indicator at zero before removing it from the clearance specifications. (The honing or boring
cylinder, and measure across the gage contact operation must be done carefully so the specified
points with an outside micrometer, with the clearance between pistons, rings, and cylinder
gage at the same zero setting when removed bores is maintained).
from the cylinder (figure 3).
3. If the cylinders are found to exceed the specified | V | Important
out-of-round or taper, honing or boring will be nec-
essary. Any cylinders that were found to have less • Refer to the proper section for additional informa
than 0.13 mm (0.005 inch) wear or taper may not tion.
entirely clean up when fitted with a high limit pis
ton. If it is desired to entirely clean up the bore in
theses cases, it will be necessary to rebore for an
HONING
oversize piston. If more than 0.13 mm (0.005 inch) 1. When honing the cylinders, follow the hone manu
taper or wear, they should be bored and honed to facturer’s recommendations for use, cleaning, and
the smallest oversize that will permit complete lubrication during honing. Use only clean, sharp
resurfacing of all cylinders. stones of the proper grade for the amount of mate
4. Fine vertical scratches made by ring ends will not, rial to be removed. Dull, dirty stones cut unevenly
by themselves, cause excessive oil consumption;
and generate excessive heat. When using coarse
therefore, honing to remove them is unnecessary.
or medium grade stones, use care to leave suffi
5. If the bore is glazed but otherwise serviceable,
cient metal so that all stone marks may be
break the glaze lightly with a hone and replace the
removed with the fine stones used for finishing to
piston rings.
provide proper clearance.
• Make sure the honing stones are clean, sharp,
and straight. Move the hone slowly up and 2. Occasionally, during the honing operation, the cyl
down to produce a 45 to 65 degree cross-hatch inder bore should be thoroughly cleaned and the
pattern. Clean the bore thoroughly with soap piston selected for the individual cylinder checked
and water. Dry and rub in clean engine oil, then for correct fit.
remeasure. 3. When honing to eliminate taper in the cylinder,
6. If honing is not required, the cylinder bores should make full strokes of the hone in the cylinder. Also
be cleaned with a hot water and detergent wash. check measurement at the top, middle, and bottom
Apply clean engine oil to the bore after cleaning. of the bore repeatedly.
GENERAL ENGINE MECHANICAL 6A-5
24086 - 8
J 24086
• Piston.
— Ring land for cracking, wear, etc.
— Ring grooves for burrs, nicks, etc.
— Skirts and pin bosses for cracking.
— Skirts for scuffing.
• Connecting rod bearing inserts for scratches or
deep pitting.
PISTON SELECTION
(2.2L ENGINES)
Refer to the proper section.
PISTON SELECTION
(ALL EXCEPT 2.2L ENGINES)
1. Check the used piston to cylinder bore clearance.
t
J 2 4 0 8 6 -9
J 24086-20
71
Figure 10— Measuring the Piston Skirt Figure 11—Installing the Piston Pin
C. Subtract the piston diameter from the cylinder C. Adjust the piston pin installer (J 24086-9) to the
bore diameter to determine piston to bore clear correct length, using the letter-number scale on
ance. the installer adjuster (figure 11). This is neces
D. Refer to “Specifications” in the proper section. sary to ensure the piston pin is pressed into the
Determine if the piston clearance is in the piston to the correct depth. Refer to the instruc
acceptable range. tions supplied with the tool for the proper set
2. If the used piston is not acceptable, determine if a ting.
new piston will fit the cylinder bore. D. Lock the adjuster in place with the lock ring.
3. If a new piston does not bring the clearance within
tolerances, the cylinder bore must be recondi
tioned. NOTICE: After the installer hub bottoms on
4. Mark the piston to identify the cylinder for which it the support assembly, do not exceed 35000
was fitted. kPa (5000 psi) pressure, as this could cause
damage to the tool.
ASSEMBLY
Assembling the Piston and Connecting Rod
E. Place the adjuster in the support fixture. Press
Assemble (Figure 11) the piston pin into place (until the adjustable
installer bottoms in the support fixture).
Tool Required: F. Remove the piston and connecting rod assem
J 24086-B Piston Pin Remover and Installer Set bly from the tool and check the piston for free
1. Piston and connecting rod. dom of movement on the piston pin.
A. The piston and connecting rod must be installed
in the proper position. Installing the Piston Rings
— 2.2L Engines: Refer to proper section.
— 5.0L and 5.7L Engines: The flange on the Measure (Figures 4 and 12)
connecting rod must face toward the front of
the piston on a left side assembly and
toward the rear of the piston on a right side Ring end gap as follows:
assembly. 1. Select rings comparable in size to the piston
— All Others: The valve cutouts in the piston
being used.
crown must be opposite the connecting rod
2. Slip the compression ring into the cylinder bore
bearing tangs.
and press it down about 7 mm (1/4 inch) above
B. Lubricate the piston pin holes in the piston and
ring travel. Make sure the ring is square with
connecting rod with engine oil.
C. Install the pin guide (item 1, figure 11) to hold the cylinder wall.
the piston and connecting rod together. Be sure 3. Measure the space or gap between the ends of
to use the proper pin guide. Refer to the the ring with a feeler gage (figure 12).
instructions supplied with the tool. 4. Refer to “Specifications” in the proper section
2. Piston pin. for correct gap.
A. Insert the piston pin into the piston pin hole. 5. If the gap between the ends of the ring is not as
B. Place the assembly on the support fixture (fig specified, remove the ring and try another for
ure 11). fit.
6A-8 GENERAL ENGINE MECHANICAL
CAMSHAFT BEARINGS
CAMSHAFT BEARING Clean
Figure 15— Removing or Installing Camshaft Figure 16—Checking Camshaft Bearing Oil Hole
Bearings Alignment (Typical)
6A-10 GENERAL ENGINE MECHANICAL
HYDRAULIC LIFTERS
Two types of hydraulic lifters are used in engines • Continue pumping for several strokes after defi
covered by this manual, flat type and roller type. Ser nite resistance is felt.
vice procedures are similar for both types. 5. Raise the weight arm to allow the plunger spring to
Hydraulic lifters are serviced only as an assembly. No expand fully. Then lower the arm onto the ram and
internal parts are available. This information is offered commence turning the crank slowly (1 revolution
for those who may wish to test valve lifters. every 2 seconds).
6. Time indicator travel from the lower line (first line
VALVE LIFTER LEAKDOWN above the set line) to the line marked 0.094 or 3/32
RATE TEST inch, while rotating the cup with the crank. The
lifter is satisfactory if the rate is between 12 and 90
(FLAT-TYPE LIFTERS ONLY) seconds.
Tool Required:
J 5790-B Hydraulic Lifter Leakdown Tester
The hydraulic lifter leakdown tester will very accurate
ly check the leakdown rate of the valve lifters (figure
17). This tool applies a measured load to the valve lifter
and measures the amount of valve lifter travel under
load. Instructions for use are furnished with the tool,
along with a supply of special test oil.
1. Fill tester cup to approximately 1 inch from the top
with the special fluid that is available from the tes
ter manufacturer.
2. Swing the weight arm out of the way. Raise the
arm and position the lifter into the boss in the cen
ter of the tester cup.
3. Adjust the ram (with the weight arm clear of the
ram) so that the point is positioned on the set line
(marked “S”). Tighten the jam nut to maintain the
setting.
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 Figure 17—Testing the Hydraulic Lifter
(Flat Type Only)
• Lifter must be completely submerged at all
times.
GENERAL ENGINE MECHANICAL 6A-11
CYLINDER HEAD
DISASSEMBLY Valve stems and heads on a wire wheel.
Carbon and old gasket from the cylinder head gas
Disassemble ket surface.
Tools Required:
J 8001 Dial Indicator (or equivalent)
J 9666 Valve Spring Tester
Valve stem to guide bore clearance.
— Excessive valve stem to guide bore clearance
will cause excessive oil consumption and may
cause valve breakage. Insufficient clearance will
result in noisy and sticky functioning of the
valve and disturb the engine’s smoothness.
A. Clamp a dial indicator (J 8001 or equivalent) on
one side of the cylinder head rocker arm cover
Figure 18—Cleaning the Combustion Chambers gasket rail (figure 20).
(Typical)
REPAIR
VALVE GRINDING
Pitted valves must be refaced to the proper angle.
Valve stems that show excessive wear, or valves that
are warped excessively must be replaced. When an
excessively warped valve head is refaced, a knife edge
will be ground on part or all of the valve head due to
the amount of metal that must be removed to complete
ly reface. Knife edges lead to breakage, burning, or
preignition due to heat localizing on this knife edge. If
the edge of the valve head is less than 0.80 mm (1/32
inch) after grinding, replace the valve (figure 23).
Several different types of equipment are available for
refacing valves. The recommendation of the manufac
turer of the equipment being used should be carefully
followed to attain the proper results.
Refer to “Specifications” in the proper section for
valve face angle specifications.
Figure 25— Measuring the Crankshaft Journals Figure 26—Checking Crankshaft Run-Out
GENERAL ENGINE MECHANICAL 6A-15
Important
• If a bearing is being fitted to an out-of-round Figure 29—Placing the Gauging Plastic on the
journal, be sure to fit the maximum diameter of Connecting Rod Journal
the journal. If the bearing is fitted to the mini
mum diameter and the journal is excessively
out-of-round, interference between the bearing
and the journal will result in rapid bearing fail
ure.
3. Connecting rod cap with the lower connecting rod
bearing insert. DO NOT TURN THE CRANKSHAFT
WITH THE GAGING PLASTIC INSTALLED.
4. Connecting rod bolt nuts.
Important
* Measure (Figure 29 and 30) • Do not attempt to use shims or file the bearing to
obtain the needed clearance.
• If the clearance cannot be brought within specifica
Gaging plastic at its widest point, using the scale
tions, recondition or replace the crankshaft. Do not
on the gaging plastic envelope (figure 30).
recondition a rolled fillet crankshaft.
If the clearance exceeds specifications, select a
new, correct size, connecting rod bearing and 4- + Remove or Disconnect
remeasure the clearance.
A standard or undersize bearing may produce the Gaging plastic.
proper clearance. Refer to the proper section for
bearing availability.
GENERAL ENGINE MECHANICAL 6A-17
THREAD REPAIR
Damaged threads may be reconditioned by drilling
out, rethreading, and installing a suitable thread insert.
Tools Required:
General purpose thread repair kits are available
commercially.
Important
Important
Important
SPECIAL TOOLS
3- | o e J 6 0 9 8 " 0 1 7- J 8001
F9534
4.3L V 6 (V IN Z) 6A3B-1
SECTION 6A3B
4.3L V6
RPO LB4, VIN Z
CAUTION: On vehicles equipped with Supplemental inflatable Restraint (SIR), refer to CAUTIONS in
Section 9J under “ON-VEHICLE SERVICE” and the SIR Component and Wiring Location view in Section
9J before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could
result in possible air bag deployment, personal injury or otherwise SIR repairs.
NOTICE: Always use the correct fastener in the correct location. Use the correct fastener part number to
replace a fastener. If the correct fastener part number is not available, a fastener of equal size and
strength may be used. Do not use a fastener that is stronger when the correct fastener part number is not
available in the following applications:
• Some bolts are designed to permanently stretch, and if a stronger fastener is used, the part will not be
tightened correctly. These permanently stretching bolts will be called out. The correct part number
fasteners must be used to replace this type of fastener because there is no available equivalent.
• Other bolts are designed to break if over tightened to prevent part damage. Using a stronger fastener may
cause part damage to occur. Fasteners that need to be replaced when removed will be called out. The
correct tightening specification and sequence must be used when installing fasteners. Part or system
damage may occur if the above instructions are not followed.
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................6A3B- 3
Engine Construction.......................................................................................................................................... 6A3B- 3
Cylinder Block..................................................................................................................................................6A3B- 3
Cylinder Heads................................................................................................................................................ 6A3B- 3
Crankshaft......................................................................................................................................................... 6A3B- 3
Cam shaft........................................................................................................................................................... 6A3B- 3
Pistons and Connecting Rods.....................................................................................................................6A3B- 3
Balance S h aft...................................................................................................................................................6A3B- 3
Valve T rain.................. ..................................................................................................................................... 6A3B- 3
Intake Manifold.................................................................................................................................................6A3B- 3
Engine Lubrication............................................................................................................................................. 6A3B- 3
Disassembly of the Engine...................................................................................................................................6A3B- 8
Tools and Shop Equipment.............................................................................................................................. 6A3B- 8
Accessory Removal.................. ......................................................................................................................... 6A3B- 8
Cleaning.................................................................................................................................................................6A3B- 9
Draining the Engine........................................................................................................................................... 6A3B- 9
EGR Valve Removal...........................................................................................................................................6A3B- 9
Exhaust Manifold Removal............................................................................................................................... 6A3B- 9
Coolant Pump Removal.....................................................................................................................................6A3B- 9
Rocker Arm Cover Removal............................................................................................................................ 6A3B- 9
Intake Manifold Removal...................................................................................................................................6A3B- 9
Valve Train Component Removal....................................................................................................................6A3B- 9
Cylinder Head Removal.....................................................................................................................................6A3B- 9
Torsional Damper Removal.......................................................................................... ................................... 6A3B- 9
Oil Pan Removal................................................................................................................................................. 6A3B-11
Oil Pump Removal.............................................................................................................................................. 6A3B-12
Flywheel Removal............................................................................................................................................... 6A3B-12
Front Cover Removal.........................................................................................................................................6A3B-12
Timing Chain and Camshaft Sprocket Removal............................................................. ............ .............. 6A3B-12
Camshaft Rem oval.............................................................................................................................................6A3B-12
6A3B-2 4.3L V6 (VIN Z)
CONTENTS (cont’d)
SUBJECT PAGE
Balance Shaft Removal................................................................................................. ....................................6A3B-13
Piston And Connecting Rod Removal...........................................................................................................6A3B-13
Crankshaft Rear Oil Seal Removal................................................................................................................ 6A3B-14
Crankshaft Rear Oil Seal Retainer Removal............................................................................................... 6A3B-14
Crankshaft Removal............................................................................................................................... ........... 6A3B-14
Main Bearing Removal (Without Removing Crankshaft)................................................. ........................ 6A3B-15
Cleaning, Inspection, and Repair....................................................................................................................... 6A3B-15
Cylinder Block......................................................................................................................................................6A3B-15
Cylinder Bore................................................................................................................................................... 6A3B-16
Piston And Connecting Rod Assembly.........................................................................................................6A3B-17
Intake and Exhaust Manifolds.........................................................................................................................6A3B-17
Camshaft............................................................................................................................................................... 6A3B-18
Camshaft Bearings............................................................................................................................................. 6A3B-18
Timing Chain and Sprockets...........................................................................................................................6A3B-18
Crankshaft Sprocket Replacement............................................................................................................. 6A3B-18
Front Cover..........................................................................................................................................................6A3B-18
Coolant Pum p......................................................................................................................................................6A3B-19
Oil Pan and Rocker Arm Covers................................................................................................................... 6A3B-19
Oil Pump............................................................................................................................................................... 6A3B-19
Valve Train Components................................................................................................................................... 6A3B-21
Pushrods, Rocker Arms, Balls, and Nuts................................................................................................ 6A3B-21
Hydraulic Lifters................................................................................................................................................. 6A3B-21
Cylinder Head.......................................................................................................................................................6A3B-21
Rocker Arm Stud Replacement.................................................................................................................. 6A3B-22
Thermostat and Coolant Outlet.......................................................................................................................6A3B-23
Torsional Damper............................................................................................................................................... 6A3B-23
Crankshaft and Bearings.................................................................................................................................. 6A3B-23
Assembly of the Engine........................................................................................................................................6A3B-24
Prior to Assembly............................................................................................................................................... 6A3B-24
Crankshaft and Main Bearing Installation.....................................................................................................6A3B-24
Inspecting Crankshaft End Play................................................................................................................. 6A3B-24
Crankshaft Rear Oil Seal Retainer Installation........................................................................................... 6A3B-25
Crankshaft Rear Oil Seal Installation............................................................................................................ 6A3B-25
Camshaft Installation ......................................................................................................................................... 6A3B-25
Balance Shaft Installation................................................................................................................................. 6A3B-26
Timing Chain and Sprocket Installation........................................................................................................6A3B-27
Front Cover Installation.....................................................................................................................................6A3B-28
Torsional Damper Installation..........................................................................................................................6A3B-28
Piston And Connecting Rod Installation.......................................................................................................6A3B-28
Connecting Rod Bearing Selection............................................................................................................ 6A3B-28
Oil Pump Installation..........................................................................................................................................6A3B-29
Oil Pan Installation............................................................................................................................................. 6A3B-30
Cylinder Head Installation................................................................................................................................6A3B-30
Valve Train Component Installation............................................................................................................... 6A3B-31
Valve Adjustment................................................................................................................................................ 6A3B-31
Intake Manifold Installation.............................................................................................................................. 6A3B-31
Rocker Arm Cover Installation........................................................................................................................6A3B-33
Exhaust Manifold Installation...........................................................................................................................6A3B-34
EGR Valve Installation.......................................................................................................................................6A3B-34
Flywheel Installation........................................................................................................................................... 6A3B-34
Coolant Pump Installation................................................................................................................................ 6A3B-35
Engine Accessory Installation.........................................................................................................................6A3B-35
Engine Set-Up and Testing.............................................................................................................................. 6A3B-35
Specifications..........................................................................................................................................................6A3B-36
Engine Specifications........................................................................................................................................6A3B-36
Fastener Tightening Specifications................................................................................................................ 6A3B-38
Special Tools................................ .......................................................................................................................... 6A3B-39
4.3L V6 (V IN Z) 6A3B-3
GENERAL DESCRIPTION
ENGINE CONSTRUCTION BALANCE SHAFT
The 4.3L (262 CID) (VIN Z) engine is a liquid-cooled A cast-ductile balance shaft is mounted in the crank
90-degree V6 type with overhead valves, cast-iron case above and inline with the camshaft for enhanced
block, cylinder heads, and cast-ductile balance shaft. engine smoothness under all operating conditions. A
For engine identification, refer to SECTION OA. For camshaft gear drives the gear attached to the balance
engine component identification refer to figures 1 shaft. The front end of the balance shaft is supported
through 4. by a ball bearing and the opposite end uses a sleeve
bearing.
CYLINDER BLOCK
The cylinder block has 6 cylinders arranged in a “V” VALVE TRAIN
shape with 3 cylinders in each bank. Starting at the
front of the engine, cylinders in the right bank are num The valve train is a ball pivot type. Motion is transmit
bered 1-3-5 and cylinders in the left bank are numbered ted from the camshaft through the hydraulic lifter and
2-4-6 (when viewed from the front of the engine). The pushrod to the rocker arm. The rocker arm pivots on its
firing order of the cylinders is 1-6-5-4-3-2. The cylinders ball and transmits the camshaft motion to the valve.
The hydraulic valve lifters with roller followers keep all
are encircled by coolant jackets.
parts of the valve train in constant contact. Each lifter
CYLINDER HEADS acts as an automatic adjuster and maintains zero lash
The cylinder heads have one intake and one exhaust in the valve train and eliminates the need for periodic
valve for each cylinder. A spark plug is located between valve adjustment.
the valves in the side of the cylinder head. The valve
guides are integral and the rocker arms are retained on INTAKE MANIFOLD
individual threaded-in studs. A cast-aluminum intake manifold is used that has an
exhaust gas recirculation (EGR) port cast into it for the
CRANKSHAFT
mixture of exhaust gases with the fuel and air mixture.
The crankshaft is supported by four main bearing
inserts. The number four bearing at the rear of the
engine is the end thrust bearing. The bearings are ENGINE LUBRICATION
retained by bearing caps that are machined with the A lubrication schematic is shown in figure 5. The gear
block for proper alignment and clearances. type oil pump is driven from the distributor shaft, which
CAMSHAFT is gear driven from the camshaft. Oil is drawn into the
The camshaft is supported by four full round, sleeve oil pump through a pickup screen and pipe.
type bearings. A sprocket on the crankshaft drives a Pressurized oil is routed to the oil filter. In case of
timing chain which in turn drives the camshaft through a excessive oil pressure, a bypass valve is provided. Fil
sprocket. tered oil flows into the main gallery and then to the
camshaft, balance shaft rear bearing, and crankshaft
PISTONS AND CONNECTING RODS bearings. The valve lifter oil gallery supplies oil to the
The pistons are made of cast aluminum alloy using valve lifters. Oil flows from the hydraulic lifters through
two compression rings and one oil control ring. Piston the hollow pushrods to the rocker arms. Oil from over
pins are offset 1.6 mm (1/16 inch) toward the major head drains back to the crankcase through oil drain
thrust side (right side) to reduce piston slap as the holes.
connecting rod travels from one side of the piston to the The timing chain is drip fed from the front camshaft
other side after a stroke. The pins are a press fit in the bearing. The pistons and piston pins are lubricated by
connecting rod and a floating fit in the piston. oil splash.
3706S3001
V3703
1. BOLT
2. COVER, VALVE ROCKER ARM (CK/G/ML)
3. COVER, VALVE ROCKER ARM (P,ST)
3006r4807
_______________________________________
Figure 6— Rocker Arm Cover and Components
19. BOLT
20. GUIDE ASSEMBLY
21. NUT
22. BALL
23. ARMS, ROCKER
24. PUSHROD
26. LIFTER, HYDRAULIC
3706S2910
Tool Required:
J 39046 Torsional Damper Puller and Installer
34. NUT
35. STUD
36. KEY
37. GEAR, BALANCE SHAFT DRIVE
38. SPROCKET, CRANKSHAFT
39. BOLT
40. SPROCKET, CAMSHAFT
41. CHAIN, TIMING
V2629
FLYWHEEL REMOVAL
Remove or Disconnect
1. Flywheel bolts.
2. Flywheel.
Important
A.
Remove or Disconnect
Figure 15—Removing the Connecting Rod and • Crankshaft rear oil seal. Insert a screwdriver into
Piston the notches provided in the seal retainer and pry
the seal out (figure 16).
• Marking them from the front to the rear, with the
engine in an upright position and viewed from
the front:
CRANKSHAFT REAR OIL SEAL
— The right bank is numbered 1-3-5. RETAINER REMOVAL
— The left bank is numbered 2-4-6.
3. Check the connecting rod and cap for identification Remove or Disconnect (Figure 17)
marks.
• Mark the parts if required. 1. Screws (50) and nuts (51).
• Marking them from the front to the rear, with the 2. Seal retainer (52).
engine in an upright position and viewed from 3. Gasket (54).
the front:
•T h e right bank is numbered 1-3-5. CRANKSHAFT REMOVAL
• The left bank is numbered 2-4-6.
Important
Important
Check the main bearing caps for location markings.
• Store the connecting rod, bearings and cap togeth Mark the caps if necessary. The caps must be
er as mating parts, so they may be reassembled in returned to their original locations during assembly.
the same position from which they were removed.
4. Connecting rod cap. Remove or Disconnect
5. Connecting rod and piston.
• Attach J 5239 to the connecting rod bolts (fig 1. Main bearing cap bolts.
ure 15). 2. Main bearing caps and lower main bearing inserts.
• Use the long guide rod of J 5239 to push the 3. Crankshaft from the cylinder block with extreme
connecting rod and piston out of the bore care, taking care to avoid damage to crankshaft
through the top of the engine. journals and thrust flange surfaces.
6. Connecting rod bearings. 4. Upper main bearing inserts.
4.3L V6 (VIN Z) 6A3B-15
A. Rear of Block
50. Screw
51. Nut
52. Retainer
53. Stud
54. Gasket
V0516
* Disassemble
Components as required.
Marking parts if required.
Marking parts 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.
| Clean
Cylinder Bore Reconditioning
Refer to SECTION 6A. Components as outlined.
Components as outlined.
NOTICE: For steps 2, 4, 5, and 6 refer to “No-
tice” on page 6A3B-1. € Measure
Sprocket.
Keyway and threads.
— Galling
— Gouges
— Overheating
Measure
CAMSHAFT BEARINGS
Refer to SECTION 6A for replacement procedures.
I? Inspect
Tool Required:
J 35468 Front Cover Aligner and Oil Seal
Installer
4.3L V 6 (V IN Z) 6A3B-19
J 35468
V0520
V0519 Inspect
Figure 23— Installing the Crankshaft Sprocket
Gasket flanges for bending or damage.
• New seal so that the open end of the seal is Rubber grommets and parts on the rocker arm cov
toward the inside of the cover. er for deterioration.
A. Support the cover at the seal area. Oil pan for rock damage or cracks.
B. Drive the seal into position with J 35468. Oil pan deflector for lack of fit.
C. Lubricate the seal with engine oil before install Drain plug threads for stripping.
ing the torsional damper.
OIL PUMP
COOLANT PUMP +-► Remove or Disconnect (Figure 25)
jjjj| Clean
1. Shaft extension (1).
• All gasket mating surfaces. Be sure old gasket • Do not remove the pickup pipe and screen unless
material is removed and free of oil or other foreign replacement is required.
materials. • The pickup pipe has a press fit in to the pump
cover.
Notice: Do not immerse the pump in solvent.
• Do not remove the screen from the pipe. The pick
The solvent may enter the pump’s perma
up screen and pipe are serviced as a complete
nently lubricated bearings and cause prema
assembly only.
ture bearing failure.
2. Pickup pipe and screen (10).
9 Inspect 3. Screws (9).
4. Pump cover (5).
• Coolant pump shaft for rotation and end play. The • Mark where the idler gear (4) and drive gear (3)
shaft and fan hub should turn straight and smooth mesh together, so they can be reinstalled with the
ly. If the hub wobbles or the shaft is noisy or feels same gear teeth indexed.
6A3B-20 4.3L V6 (VIN Z)
Tool Required:
1. Shaft Extension J 21882 Pickup Tube and Screen Installer
2. Pump Body 1. Pressure regulator valve (6) into the pump cover.
3. Drive Gear and Shaft 2. Pressure regulator spring (7) into the pump cover.
4. Idler Gear 3. Retaining pin (8) into the pump cover.
5. Pump Cover 4. Drive gear and shaft (3) into the pump body.
6. Pressure Regulator Valve 5. Idler gear (4) into the pump body.
7. Pressure Regulator Spring • Match together the index marks on the two
8. Retaining Pin gears made during disassembly.
9. Screws 6. Pump cover (5).
10. Pickup Screen and Pipe
B9445
NOTICE: Refer to “Notice” on page 6A3B-1.
Figure 25— Oil Pump Components
7. Screws (9).
5. Idler gear (4) and drive gear (3).
6. Retaining pin (8).
Tighten
7. Pressure regulator spring (7).
8. Pressure regulator valve (6).
• Screws to 9 N-m (80 lbs. in.).
jjj| Clean • With the shaft extension (1) installed on the pump,
turn the drive shaft by hand to check for smooth
• All parts in clean solvent and dry them with com operation.
pressed air.
NOTICE: Be careful of twisting, shearing, or
Inspect (Figure 25)
collapsing the pipe when installing it to the
pump. A damaged pipe can cause lack of
• Pump body (2) for cracks, wear, or other damage.
• Inside of the cover (5) for cracks and wear that
lubrication and engine failure.
would permit oil to leak past the ends of the gears.
• Gears (3 and 4) for wear. 8. Pickup screen and pipe.
• Drive gear and shaft (3) for lack of fit in the pump A. If the pickup screen and pipe assembly was
body (2). removed, it should be replaced with a new part.
• The pump gears, cover, and body are not serviced Loss of press fit condition could result in an air
separately. If any of the parts are damaged or leak and loss of oil pressure.
worn, the entire oil pump assembly must be B. Mount the oil pump in a soft-jawed vise.
replaced. C. Apply sealer to the end of the pipe.
• Pickup screen and pipe (10) for damage to the D. Tap the pickup screen and pipe into place,
screen or loose fit of the pipe. using J 21882 and a hammer.
F9471
E. The pump screen must be parallel with the bot 1. Valve keepers (67).
tom of the oil pan when installed. A. Compress the springs with J 8062 (figure 28).
9. Oil pump drive shaft and connector (1). B. Remove the keepers (67).
C. Remove J 8062.
VALVE TRAIN COMPONENTS 2. Intake valve components (figure 27).
A. Cap (68).
Important B. Shield (69).
C. Seal (71).
• Store all reusable components in an exact order, D. Damper (72).
so they may be reassembled in the same position E. Spring (73).
from which they were removed.
3. Exhaust valve components (figure 27).
PUSHRODS, ROCKER ARMS, BALLS, AND NUTS A. Rotator (75).
B. Shield (69).
Clean C. Seal (71).
D. Damper (72).
• All parts in clean solvent and dry them with com E. Spring (73).
pressed air.
• Make sure the oil passages through the pushrods 4. O-ring seals (70).
are clear. 5. Valves (74 and 76).
• Place the valves (74 and 76) in an organizer
L* Inspect rack so they can be replaced in their original
position at reassembly.
Rocker arms and balls at their mating surfaces.
These surfaces should be free from wear or dam
67. Valve Keeper 73. Spring
age.
Rocker arm areas that contact the valve stems and 68. Cap 74. Intake Valve
the socket areas that contact the ends of the push 69. Shield 75. Rotator
rods. These areas should be free of wear or dam 70. O-Ring Seal 76. Exhaust Valve
age. 71. Seal
Rocker arm nuts. 72. Damper
Pushrod ends for scoring, roughness, or bends.
— Roll the pushrod on a flat surface to determine
its straightness. If the rod is bent, the rod will
not roll freely. Replace if necessary.
HYDRAULIC LIFTERS
The type of hydraulic lifters used in this engine are
the roller type.
Hydraulic lifters are serviced only as an assembly. No
internal parts are available. Service is limited to a
V0522
disassembly and cleaning. Discard any valve lifter (s)
that are worn. Figure 27—Valves and Components
Important
CYLINDER HEAD
Cylinder head disassembly is covered in this proce
dure. Refer to SECTION 6A for information regarding
the following:
• Cleaning
• Inspection
• Measuring clearances
• Valve grinding
• Valve guide reconditioning
Tool Required:
J 8062 Valve Spring Compressor
6A3B-22 4.3L V6 (VIN Z)
Remove or Disconnect
Install or Connect
Tighten
XJJP Clean
• Components as outlined.
L1 Inspect
Kyi Clean
NOTICE: For steps 4 and 6, refer to “Notice’ — Firmly thrust the crankshaft first rearward then
on page 6A3B-1. forward. This will line up the rear main bearing
and crankshaft thrust surfaces.
Tighten
Measure
m Inspect
Tighten
Install or Connect (Figure 33) • Coat the camshaft lobes and journals with a high
quality engine oil supplement (GM Engine Oil Sup
Tool Required: plement or equivalent).
J 35621 Seal Installer •Apply Engine Oil Supplement (GM P/N 1052367),
or equivalent to all the teeth on the distributor drive
gear.
A. Rear of Block
1.Two or three 5/16-18 bolts 100-125 mm (4-5
50. Screw
inches) long into the camshaft threaded holes. Use
51. Nut
these bolts to handle the camshaft.
52. Retainer
2. Camshaft to the engine (figure 35). Handle the
53. Stud camshaft carefully to prevent damage to the cam
54. Gasket 53 shaft bearings.
52 £ Tighten
34. NUT
35. STUD
36. KEY
37. GEAR, BALANCE SHAFT DRIVE
38. SPROCKET, CRANKSHAFT
39. BOLT
40. SPROCKET, CAMSHAFT
41. CHAIN, TIMING
V2629
Tighten
Tighten
Figure 35—Installing Camshaft • Rotate balance shaft (47) by hand to make sure
there is clearance between the balance shaft (47)
BALANCE SHAFT and retainer (43). If balance shaft (47) does not
rotate freely, check to be sure retaining ring on
INSTALLATION front bearing is seated on case.
Install or Connect (Figures 36 and 37) • Turn the camshaft so, with the balance shaft drive
gear temporarily installed, the timing mark on the
drive gear is straight up.
• With the balance shaft drive gear removed, turn the
NOTICE: For ste p s 3, 4, and 6, refer to “No
tice” on page 6A3B-1 balance shaft so the timing mark on the driven
gear points straight down.
Tools Required: 5. Balance shaft drive gear (37) onto camshaft.
J 38834 Balance Shaft Bearing Service Kit
J 36996 Balance Shaft Installer Important
J 8092 Driver Handle
J 36660 Torque/Angle Meter
• Make sure the timing marks on the balance
1. Balance shaft rear bearing (45) using J 38834 (fig
shaft drive gear and driven gear line up (figure
ure 36).
37).
• Dip bearing in clean engine oil before installa
tion. 6. Balance shaft drive gear bolt.
2. Balance shaft (47) into block using J 36996 and
J 8092. & Tighten
A. Dip the front balance shaft bearing into clean
engine oil before assembly. Bolt to 16 N-m (12 lbs. ft.).
4.3L V6 (VIN Z) 6A3B-27
Important
Tighten
Gear Timing Marks
• Camshaft sprocket bolts (39) and nut (34) to 28
N-m (21 lbs. ft.).
6A3B-28 4.3L V6 (VIN Z)
Important
tjj Measure
& Tighten
Measure
Clearance
NOTICE: Refer to “Notice” on page 6A3B-1.
2. Oil pump to main bearing cap bolt.
Tighten
1. Head gasket.
3. Cylinder head bolts. Coat threads of the cylinder
• Do not use sealer on composition gaskets.
head bolts with sealing compound (GM P/N
• Place the gasket over the block dowel pins.
2. Cylinder head. Carefully guide the cylinder head 1052080) or equivalent and install finger-tight.
into place over the dowel pins and gasket.
4.3L V6 (VIN Z) 6A3B-31
Tighten 3. Pushrods.
A. Seat the pushrods into the socket of the
• Cylinder head bolts in three steps, using the hydraulic lifters.
sequence shown in figure 45. B. Coat mating surfaces of the rocker arms (23)
A. The first sequence to 34 N-m (25 lbs. ft.). and balls (22) with Engine Oil Supplement (GM
B. The second sequence to 61 N-m (45 lbs ft.). P/N 1052367) or equivalent.
C. Final torque sequence to 90 N-m (65 lbs.
ft.). 4. Rocker arms (23) with balls (22) on to the prop
er stud.
4. Engine lift bracket.
5. Rocker arm nuts (21) on to the studs.
VALVE TRAIN COMPONENT • Align the push rod into the rocker arm while
tightening rocker arm nut (21).
INSTALLATION
Important
Important
• No lash adjustment is needed.
Replace all hydraulic lifters, change the engine oil
and filter and add GM Engine Oil Supplement (GM
P/N 1052367 or equivalent) to the engine oil when
VALVE ADJUSTMENT
ever a new camshaft is installed. The 4.3L VIN Z engine has screw-in rocker arm studs
with positive stop shoulders, no valve adjustment is
Install or Connect (Figures 46 and 47) necessary. When the valve train requires service, you
simply tighten the rocker arm nuts to 27 N-m (20 Ibs.ft.).
Lubricate the hydraulic lifter bodies and feet with
Engine Oil Supplement (GM P/N 1052367) or
equivalent.
INTAKE MANIFOLD
1. Hydraulic lifters to the block. INSTALLATION
2. Guide assembly.
Install or Connect (Figures 47 and 48)
a Tighten
1. Gaskets to the cylinder head with the port blocking
Guide assembly bolts to 16 N-m (12 lbs. ft.). plates facing the rear of the engine.
19. BOLT
20. GUIDE ASSEMBLY
21. NUT
22. BALL
23. ARMS, ROCKER
24. PUSHROD
26. LIFTER, HYDRAULIC
V2974
a Tighten
NOTICE: Refer to “Notice” on page 6A3B-1. • Bolts to 22 N-m (16 lbs. ft.).
COOLANT PUMP INSTALLATION 3. Fill the cooling system with the proper quantity and
grade of coolant. Refer to SECTION 6B1.
-►+ Install or Connect
Important
1. Gaskets.
• Whenever the cooling system is serviced or
2. Coolant pump.
drained for service procedures, 2 coolant seal
ant pellets, (GM P/N 3634621) or equivalent,
NOTICE: Refer to “Notice” on page 6A3B-1. must be added to the cooling system.
• The pellets must be added to the radiator or the
3. Coolant pump bolts. pressurized coolant reservoir.
— Pellets must be crushed prior to installation.
& Tighten
• Do not place pellets into a non-pressurized
coolant recovery reservoir. On these systems,
• Coolant pump bolts to 40 N-m (30 lbs. ft.). the pellets must be added to the radiator.
• The sealant pellets may leave a film on the
ENGINE ACCESSORY sides of pressurized and non-pressurized cool
INSTALLATION ant recovery reservoirs. This film is normal.
4. Crank the engine several times. Listen for any
Install the engine accessories (distributor, oil filter,
unusual noises or evidence that parts are binding.
generator, etc.) as directed in the proper on-vehicle
5. Use the proper on-vehicle Truck Service Manual or
Truck Service Manual. Connect all vacuum hoses and
Emission Control Label for specifications on igni
electrical equipment the same way as removed.
tion timing adjustment.
6. Start the engine and listen for unusual noises.
ENGINE SET-UP AND TESTING 7. Run the engine speed at about 1000 RPM until the
After overhaul, the engine should be tested before engine is at operating temperature.
installing it in the vehicle. 8. Listen for sticking lifters and other unusual noises.
1. Install oil filter. 9. Check for oil and coolant leaks while the engine is
2. Fill the crankcase with the proper quantity and running.
grade of engine oil.
Important
SPECIFICATIONS
ENGINE SPECIFICATIONS (4.3L)
AH Specifications are in INCHES unless otherw ise noted.
GENERAL DATA:
Type V6
Displacement 4.3L (262 Cu. In.)
RPO (VIN Code) LB4 (Z)
Bore 4.00
Stroke 3.48
Compression Ratio 9.10*
Firing Order 1-6-5-4-3-2
Oil Pressure (Minimum HOT) 6 psi @ 1000 RPM; 18 psi @ 2000 RPM; 24 psi @ 4000 RPM
CYLINDER BORE:
Diameter 4.0007-4.0017
Out Of Production 0.001 (Maximum)
Round Service 0.002 (Maximum)
Thrust Side 0.0005 (Maximum)
Production
Taper Relief Side 0.001 (Maximum)
Service 0.001 (Maximum)
PISTON:
Production 0.0007-0.0024
Service Limit 0.0024 (Maximum)
PISTON RING:
C Top
0 Production 0.0012-0.0032
Groove 2nd
M
P Clearance
R Service Limit 0.0042 (Maximum)
E Top
s 0.010-0.020
Production
S 2nd 0.010-0.025
1
0 Service Limit 0.035 (Maximum)
N
Groove Production 0.002-0.007
0 Clearance Service Limit
1 0.008 (Maximum)
1 Production 0.015-0.055
Gap
Service Limit 0.065
PISTON PIN:
Diameter 0.9270-0.9273
Clearance Production 0.0002-0.0007
In Piston Service Lmit 0.001 (Maximum)
Fit In Rod 0.0008-0.0016 Interference
EXHAUST MANIFOLD:
Surface Flatness 0.010 (Maximum)
INLET MANIFOLD:
Surface Flatness 0.010 (Maximum)
CYLINDER HEAD:
Surface Flatness 0.004 (Overall)
BALANCE SHAFT:
Front Bearing Journal Diameter 2.1648-2.1654
Rear Bearing Journal Diameter 1.4994-1.500
Rear Bearing Journal Clearance 0.001-0.0036
*Except Vehicles with a GVW rating of 8500 lbs. or greater. Compression ratio is 8.30.
T2748
4.3L V6 (VIN Z) 6A3B-37
SPECIFICATIONS
ENGINE SPECIFICATIONS (4.3L) (CONT.)
All Specifications are in INCHES unless otherw ise noted.
DISPLACEMENT: 4.3L (LB4, VIN Z)
CRANKSHAFT:
#1 2.4484-2.4493
Diameter #2, #3 2.4481-2.4490
#4 2.4479-2.4488
Main 0.0002 (Maximum)
Production
Journal Taper
Service Limit 0.001 (Maximum)
Out Of Production 0.0002 (Maximum)
Round Service Limit 0.001 (Maximum)
#1 0.0008-0.0020
Production #2, #3 0.0011-0.0023
Main #4 0.0017-0.0032
Bearing
#1 0.0010-0.0015
Clearance Service
#2, #3 .0010-0.0025
Limit
#4 0.0025-0.0035
Crankshaft End Play 0.005-0.018
Crankshaft Runout 0.001 (Maximum)
Diameter 2.2487-2.2497
Production 0.0005
Taper
Crankpin Service Limit 0.001 (Maximum)
Out Of Production 0.0005
Round Service Limit 0.001 (Maximum)
Rod Bearing Production 0.0013-0.0035
Clearance Service Limit 0.0030
Rod Side Clearance 0.015-0.046
CAMSHAFT:
Lobe Intake 0.234
Lift ± 0.002 Exhaust 0.257
Journal Diameter 1.8682-1.8692
0.004-0.012
VALVE SYSTEM:
Lifter Hydraulic
Rocker Arm Ratio 1.50:1
Intake
Valve Lash Torque Rocker Arm Nut to 27 N-m (20 lbs. ft.)
Exhaust
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) 0.002 (Maximum)
Intake 0.035-0.060
oeai vviain
Exhaust 0.062-0.093
Intake 0.0010-0.0027
Production
Stem Exhaust 0.0010-0.0027
Clearance Intake High Limit Production +0.001
Service
Exhaust High Limit Production +0.002
Free Length 2.03
Valve Closed 76-84 lbs. @ 1.70-in.
Pressure
Spring
lbs. @ in. Open 194-206 lbs. @ 1.25-in.
(Outer)
Insta led Height ± 1/32" 1.690-1.710
Valve Spring Free Length 1.86
Damper Approx # of Coils 4
T2749
6A3B-38 4.3L V6 (VIN Z)
SPECIFICATIONS (CONT.)
FASTENER TIGHTENING SPECIFICATIONS
Item N-m Lbs. Ft. Lbs. Ir
Balance Shaft Drive Gear Retaining Bolt............................................... ......... 16 12 —
Balance Shaft Driven Gear Bolt (Torque Plus a 35° Turn)................. ......... 20 15 —
Balance Shaft Retainer Bolt..................................................................... ......... 14 — 124
Camshaft Sprocket Bolts.......................................................................... ......... 28 21 —
Camshaft Thrust Plate Screws................................................................ ......... 14 — 124
Connecting Rod Bolt Nuts (Torque Plus 70°)........................................ ......... 27 20 —
Coolant Outlet Bolts................................................................................... ......... 28 21 —
Coolant Pump Bolts................................................................................... ......... 40 30 —
Crankshaft Rear Oil Seal Retainer Screws and Nuts.......................... ......... 15 11 —
Cylinder Head Bolts (In Sequence)......................................................... ......... 90 65 —
EGR Valve Bolt........................................................................................... ......... 22 16 —
Engine Block Drain Plug........................................................................... 20 15 —
Exhaust Manifold Bolts
Center Two Bolts.................................................................................... ......... 36 26 —
All Other Bolts......................................................................................... ......... 28 20 —
Flywheel Bolts............................................................................................. ......... 100 74 —
Flywheel Housing Bolts............................................................................. ......... 44 32 —
Front Cover Bolts....................................................................................... ......... 14 — 124
Hydraulic Lifter Guide Assembly Retainer Bolts.................................... ......... 16 12 —
Intake Manifold Bolts (In Sequence)....................................................... ......... 47 35 —
Main Bearing Cap Bolts............................................................................ ......... 110 81 —
Oil Filter Adapter Bolts............................................................................... ......... 22 16 —
Oil Gallery Plug, Left R e a r....................................................................... ......... 40 30 —
Oil Gallery Plug, Right Rear..................................................................... ......... 40 30 —
Oil Gallery Plug, Left Side Rear.............................................................. ......... 30 22 —
Oil Pan Bolts............................................................................................... ......... 11 — 97
Oil Pan Drain Plug..................................................................................... ......... 25 18 —
Oil Pan Nuts................................................................................................ ......... 23 17 —
Oil Pan Studs to Oil Seal Retainer or Engine Block........................... ......... 23 17 —
Oil Pressure Fitting..................................................................................... ......... 11 — 97
Oil Pump Bolt.............................................................................................. ......... 88 65 —
Oil Pump Cover Bolts................................................................................ ......... 9 — 80
Rocker Arm Cover Bolts........................................................................... ......... 10 — 90
Rocker Arm Nuts........................................................................................ ......... 27 20 —
Rocker Arm Stud........................................................................................ ......... 47 35 —
Torsional Damper Bolt................................................................................ 95 70
T2
4.3L V6 (VIN Z) 6A3B-39
SPECIAL TOOLS
• J 39046
J 5 8 0 2 -0 1
V *
9. J 5715
2. J 8062 10 . J 6036
11 . J 6880
jj(|
3. J 35468
12 . J 5825-A
4. J 8080
J 8037
13. J 5590
J 5239
14. J 35621
7. J 23738-A
15. J 36660
SECTION 6A4B
4.3L V6
RPO L35, VIN W
CAUTION: On vehicles equipped with Supplemental inflatable Restraint (SIR),refer to CAUTIONS in Section 9J
under “ON-VEHICLE SERVICE” and the SIR Component and Wiring Location view in Section 9J before
performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible
air bag deployment, personal injury or otherwise SIR repairs.
NOTICE: Always u se the correct fastener in the correct location. Use the correct fastener part num ber to
replace a fastener. If the correct fastener part num ber is not available, a fastener o f equal size and
strength m ay be used. Do n o t u se a fastener that is stronger when the correct fastener part num ber is not
available in the following applications:
• Som e bolts are designed to permanently stretch, and if a stronger fastener is used, the part will not be
tightened correctly. These perm anently stretching bolts will be called out. The correct part num ber
fasteners m ust be used to replace this type o f fastener because there is no available equivalent.
• Other bolts are designed to break if over tightened to prevent part damage. Using a stronger fastener may
cause part damage to occur. Fasteners that need to be replaced when removed will be called out. The
correct tightening specification and sequence m ust be used when installing fasteners. Part or system
damage may occur if the above instructions are not followed.
CONTENTS
SUBJECT PAGE
General Description............................................................................................................................................... 6A4B- 3
Engine Construction.......................................................................................................................................... 6A4B- 3
Cylinder Block..................................................................................................................................................6A4B- 3
Cylinder Heads................................................................................................................................................ 6A4B- 3
Crankshaft......................................................................................................................................................... 6A4B- 3
Camshaft........................................................................................................................................................... 6A4B- 3
Pistons and Connecting Rods.....................................................................................................................6A4B- 3
Balance S haft.................................................................................................................................................. 6A4B- 3
Valve Train ........................................................................................................................................................ 6A4B- 3
Intake Manifolds.............................................................................................................................................. 6A4B- 3
Engine Lubrication............................................................................................................................................. 6A4B- 3
Disassembly of the Engine...................................................................................................................................6A4B- 8
Tools and Shop Equipment.............................................................................................................................. 6A4B- 8
Accessory Removal............................................................................................................................................ 6A4B- 8
Cleaning................................................................................................................................................................ 6A4B- 9
Draining the Engine........................................................................................................................................... 6A4B- 9
Exhaust Manifold Removal............................................................................................................................... 6A4B- 9
Coolant Pump Removal.....................................................................................................................................6A4B- 9
Rocker Arm Cover Removal............................................................................................................................ 6A4B- 9
EGR Valve Rem oval........................................................................................................................................... 6A4B- 9
Upper Intake Manifold Removal......................................................................................................................6A4B- 9
Lower Intake Manifold Removal......................................................................................................................6A4B- 9
Valve Train Component Removal....................................................................................................................6A4B-10
Cylinder Head Removal.....................................................................................................................................6A4B-10
Torsional Damper Removal.............................................................................................................................. 6A4B-11
Oil Pan Removal................................................................................................................................................. 6A4B-11
Oil Pump Removal.............................................................................................................................................. 6A4B-11
Flywheel Removal............................................................................................................................................... 6A4B-11
Front Cover Removal.........................................................................................................................................6A4B-11
Timing Chain and Camshaft Sprocket Removal.........................................................................................6A4B-12
Camshaft Rem oval............................................................................................................................................. 6A4B-12
Balance Shaft Removal......................................................................................................................................6A4B-12
6A4B-2 4.3L V6 (VIN W)
CONTENTS (cont’d)
SUBJECT PAGE
Piston and Connecting Rod Removal...........................................................................................................6A4B-13
Crankshaft Rear Oil Seal Removal................................................................................................................ 6A4B-14
Crankshaft Rear Oil Seal Retainer Removal............................................................................................... 6A4B-14
Crankshaft Removal...........................................................................................................................................6A4B-15
Main Bearing Removal (Without Removing Crankshaft)..........................................................................6A4B-15
Cleaning, Inspection, and Repair........................................................................................................................6A4B-15
Cylinder Block......................................................................................................................................................6A4B-16
Cylinder Bore................................................................................................................................................... 6A4B-17
Piston and Connecting Rod Assembly.........................................................................................................6A4B-17
Upper and Lower Intake and Exhaust Manifolds.......................................................................................6A4B-18
Camshaft........................................................................................................................................................... ....6A4B-18
Camshaft Bearings............................................................................................................................................. 6A4B-18
Timing Chain and Sprockets........................................................................................................................... 6A4B-18
Crankshaft Sprocket Replacement............................................................................................................. 6A4B-19
Front C o ver..........................................................................................................................................................6A4B-19
Coolant Pum p......................................................................................................................................................6A4B-19
Oil Pan and Rocker Arm C overs................................................................................................................... 6A4B-20
Oil Pump............................................................................................................................................................... 6A4B-20
Valve Train Components................................................................................................................................... 6A4B-21
Pushrods, Rocker Arms, Balls, and N uts................................................................................................ 6A4B-21
Hydraulic Lifters................................................................................................................................................. 6A4B-21
Cylinder Head Disassembly............................................................................................................................. 6A4B-21
Cleaning and Inspection of Cylinder Head Components......................................................................6A4B-22
Rocker Arm Stud Replacement.................................................................................................................. 6A4B-22
Cylinder Head Assembly.................................................................................................................................. 6A4B-22
Thermostat and Coolant Outlet.......................................................................................................................6A4B-23
Torsional Dam per.............................................................................................................................................. .6A4B-23
Crankshaft and Bearings.................................................................................................................................. 6A4B-23
Crankshaft Rear Oil Seal Retainer................................................................................................................. 6A4B-24
Flywheel................................................................................................................................................................ 6A4B-24
Assembly of the Engine........................................................................................................................................6A4B-24
Prior to Assembly............................................................................................................................................... 6A4B-24
Crankshaft and Main Bearing Installation.................................................................................................... 6A4B-24
Crankshaft Rear Oil Seal Retainer Installation........................................................................................... 6A4B-25
Crankshaft Rear Oil Seal Installation............................................................................................................ 6A4B-25
Camshaft Installation.........................................................................................................................................6A4B-26
Balance Shaft Installation................................................................................................................................. 6A4B-26
Timing Chain and Sprocket Installation........................................................................................................6A4B-28
Front Cover Installation.....................................................................................................................................6A4B-28
Torsional Damper Installation..........................................................................................................................6A4B-28
Piston and Connecting Rod Installation.......................................................................................................6A4B-29
Connecting Rod Bearing Selection............................................................................................................ 6A4B-29
Oil Pump Installation.......................................................................................................................................... 6A4B-31
Oil Pan Installation............................................................................................................................................. 6A4B-31
Cylinder Head Installation................................................................................................................................ 6A4B-31
Valve Train Component Installation............................................................................................................... 6A4B-32
Lower Intake Manifold Installation................................................................................................................. 6A4B-33
Upper Intake Manifold Installation................................................................................................................. 6A4B-33
Rocker Arm Cover Installation........................................................................................................................6A4B-33
Exhaust Manifold Installation........................................................................................................................... 6A4B-34
EGR Valve Installation.......................................................................................................................................6A4B-34
Flywheel Installation........................................................................................................................................... 6A4B-35
Coolant Pump Installation................................................................................................................................ 6A4B-35
Engine Accessory Installation.........................................................................................................................6A4B-35
Engine Set-up and Testing............................................................................................................................... 6A4B-35
Specifications..........................................................................................................................................................6A4B-36
Engine Specifications........................................................................................................................................6A4B-36
Fastener Tightening Specifications................................................................................................................ 6A4B-38
Special Tools...........................................................................................................................................................6A4B-39
4.3L V6 (VIN W) 6A4B-3
GENERAL DESCRIPTION
ENGINE CONSTRUCTION shaft gear drives the gear attached to the balance shaft.
The front end of the balance shaft is supported by a
The 4.3L engine, RPO L35 (VIN W), is a liquid-cooled ball bearing and the opposite end uses a sleeve bear
90 degree V6 type with overhead valves, a balance ing.
shaft, and cast iron block and cylinder heads.
For engine identification, refer to SECTION 0A. For VALVE TRAIN
engine component identification, refer to figures 1 and The valve train is a ball pivot type. Motion is transmit
2. ted from the camshaft through the hydraulic lifter and
pushrod to the rocker arm. The rocker arm pivots on its
CYLINDER BLOCK ball and transmits the camshaft motion to the valve.
The cylinder block has 6 cylinders arranged in a “V” The hydraulic valve lifters with roller followers keep all
shape with 3 cylinders in each bank. Starting at the parts of the valve train in constant contact. Each lifter
front of the engine, cylinders in the right bank are num acts as an automatic adjuster and maintains zero lash
bered 1-3-5 and cylinders in the left bank are numbered in the valve train and eliminates the need for periodic
2-4-6 (when viewed from the front). The firing order of valve adjustment.
the cylinders is 1-6-5-4-3-2. The cylinders are encircled
by coolant jackets. INTAKE MANIFOLDS
The two-piece intake manifold assembly consists of
CYLINDER HEADS upper and lower cast aluminum manifolds. The throttle
The cylinder heads have one intake and one exhaust body is integral with the upper manifold. The lower
valve for each cylinder. A spark plug is located between manifold has an exhaust gas recirculation (EGR) port
the valves in the side of the cylinder head. The valve cast into it for the mixture of exhaust gases with the fuel
guides are integral and the rocker arms are retained on and air mixture.
individual threaded studs. The intake manifolds also house the central port
injection (CPI) system. This system uses a single injec
CRANKSHAFT tor to meter and distribute fuel to all the engine cylin
ders. The injector is housed in a fuel meter body. The
The crankshaft is supported by four main bearing fuel meter body also houses the pressure regulator.
inserts. The number four bearing at the rear of the Nylon inlet and outlet fuel lines and nylon delivery tubes
engine is the end thrust bearing. The bearings are connect to the CPI system. The delivery tubes indepen
retained by bearing caps that are machined with the dently distribute fuel to each cylinder through nozzles
block for proper alignment and clearances. located at the port entrance of each manifold runner
where the fuel is atomized.
CAMSHAFT
The camshaft is supported by four full round, sleeve ENGINE LUBRICATION
type bearings. A sprocket on the crankshaft drives a
timing chain which in turn drives the camshaft through a A lubrication diagram is shown in figure 5. The
sprocket. gear-type oil pump is driven from the distributor shaft,
which is gear driven from the camshaft. Oil is drawn
PISTONS AND CONNECTING RODS into the oil pump through a pickup screen and pipe.
Pressurized oil is routed to the oil filter. In case of
The pistons are made of cast aluminum alloy using
excessive oil pressure a bypass valve is provided. Fil
two compression rings and one oil control ring. Piston
tered oil flows into the main gallery and then to the
pins are offset 1.6 mm (1/16 inch) toward the major
camshaft, balance shaft rear bearing, and crankshaft
thrust side (right side) to reduce piston slap as the
bearings. The valve lifter oil gallery supplies oil to the
connecting rod travels from one side of the piston to the
valve lifters. Oil flows from the hydraulic lifters through
other side after a stroke. The pins are a press fit in the
the hollow pushrods to the rocker arms. Oil from over
connecting rod and a floating fit in the piston.
head drains back to the crankcase through oil drain
holes.
BALANCE SHAFT
The timing chain is drip fed from the front camshaft
The cast-ductile balance shaft is mounted in the bearing. The pistons and piston pins are lubricated by
crankcase above and inline with the camshaft. A cam oil splash.
6A4B-4 4.3L V6 (VIN W)
V3923
V3925
V0503
• Coolant drain plugs to 30 N-m (22 lbs. ft.). Remove or Disconnect (Figure 7)
2. Oil filter.
3. Oil pan drain plug and washer. 1. Lower intake manifold bolts.
& Tighten
19. BOLT
20. GUIDE ASSEMBLY
21. NUT
22. BALL
23. ARMS, ROCKER
24. PUSHROD
26. LIFTER, HYDRAULIC
3706S2910
CAMSHAFT REMOVAL
+-► Remove or Disconnect (Figures 12 through
15)
Tool Required:
J 5825-A Crankshaft Gear Remover
1. Balance shaft drive gear bolt (35).
2. Balance shaft drive gear (37).
3. Crankshaft sprocket (38), if necessary. Use
J 5825-A (figure 13).
4. Camshaft retainer bolts and camshaft retainer. V0510
5. Camshaft.
A. Install three 5/16-18 inch bolts 100-125 mm Figure 11—Oil Pump and Components
(4-5 inches) long into the camshafts threaded
holes. Use these bolts to handle the camshaft 1. Bolt (49).
(figure 14). 2. Driven gear (42).
B. Pull the camshaft out from the block being care 3. Retainer bolts (48).
ful to prevent damage to the camshaft bearings. 4. Retainer (43).
5. Balance shaft (47) using a soft faced hammer (fig
BALANCE SHAFT REMOVAL ure 15).
6. Balance shaft rear bearing (45) using J 38834 and
Remove or Disconnect (Figure 15) J 26941.
Tools Required:
J 38834 Balance Shaft Bearing Service Kit
J 26941 Bearing Remover
34. NUT
35. STUD
36. KEY
37. GEAR, BALANCE SHAFT DRIVE
38. SPROCKET CRANKSHAFT
39. BOLT
40. SPROCKET CAMSHAFT
41. CHAIN, TIMING
V2629
J 5825-A
B7879
Figure 19—Crankshaft Rear Oil Seal Retainer Figure 20— Removing Main Bearing Insert
CYLINDER BLOCK
+-► Remove or Disconnect (Figure 21)
IJJB Clean
* Disassemble
NOTICE: For ste p s 2, 4, 5, and 6 refer to “No
tice” on page 6A4B-1. Components as required.
Mark the parts if required.
Marking them from the front to the rear, with the
engine in an upright position and viewed from the
front.
— The right bank is numbered 1-3-5.
— The left bank is numbered 2-4-6.
Clean
Components as outlined.
I? Inspect
Components as outlined.
Measure
A. Feeler Gage
B. Straight Edge Piston pin diameter and clearance.
V0578
Piston-to-bore clearance and fit pistons as outlined.
Figure 22—Measuring Block Surface Flatness Ring end gap and ring clearance.
6A4B-18 4.3L V6 (VIN W)
Assemble
• Components as outlined.
• Check the connecting rod and cap for identification
marks.
•T h e numbers on the connecting rod and bearing
cap must be on the same side when installed in
the cylinder bore. If a connecting rod is ever trans
posed from block or cylinder to another, new con
necting rod bearings should be fitted and the
connecting rod should be numbered to correspond
with the new cylinder number.
L* Inspect
» Ring fit.
CAMSHAFT
Important
COOLANT PUMP
y| Clean
I? Inspect
Inspect
OIL PUMP
55. Idler Gear
Remove or Disconnect (Figure 27) 56. Pump Body
57. Pickup Pipe and Screen
1. Driveshaft (58).
58. Driveshaft
• Do not remove the pickup pipe and screen (57)
59. Retaining Pin
unless replacement is required.
— The pickup pipe has a press fit in to the pump 60. Spring
cover. 61. Pressure Regulator Valve
— Do not remove the screen from the pipe. The 62. Plug
pickup pipe and screen (57) are serviced as a 63. Drive Gear and Shaft
complete assembly only. 64. Retainer
2. Pickup pipe and screen (57) if necessary. 65. Cover
3. Bolts (66). 66. Bolt
4. Pump cover (65). V0521
• Mark where the idler gear (55) and drive gear and
shaft (63) mesh together, so they can be reinstalled Figure 27—Oil Pump Components
with the same gear teeth indexed. Pickup pipe and screen (57) for damage to the
5. Idler gear (55) and drive gear and shaft (63). screen or loose fit of the pipe.
6. Retaining pin (59). Pressure regulator valve (61) for fit. The regulator
7. Plug (62). valve should slide freely in its bore without sticking
8. Pressure regulator spring (60). or binding.
9. Pressure regulator valve (61).
Install or Connect (Figures 27 and 28)
Clean
Tool Required:
• All parts in clean solvent and dry them with J 21882 Oil Suction Pipe Installer
compressed air.
1. Pressure regulator valve (61) into the pump cover.
Inspect (Figure 27) 2. Pressure regulator spring (60) into the pump cover.
3. Plug (62).
4. Retaining pin (59) into the pump cover.
• Pump body (56) for cracks, wear, or other damage.
5. Drive gear and shaft (63) into the pump body.
• Inside of the cover (65) for cracks and wear that
6. Idler gear (55) into the pump body.
would permit oilto leak past the ends of the gears.
• Gears (55 and 63) for wear. • Match together the index marks on the two
• Drive gear and shaft (63) for lack of fit in the pump gears made during disassembly.
body (56). 7. Pump cover (65).
• The pump gears, cover, and body are not serviced
separately. If any of the parts are damaged or NOTICE: Refer to “N otice” on page 6A4B-1.
worn, the entire oil pump assembly must be
replaced. 8. Bolts (66).
4.3L V6 (VIN W) 6A4B-21
HI Tighten v 9 Inspect
• Bolts (66) to 9 N-m (80 lbs. in.). • Rocker arms and balls at their mating surfaces.
These surfaces should be free from wear or any
• With the driveshaft (58) installed on the pump, turn
damage.
the driveshaft by hand to check for smooth opera
• Rocker arm areas that contact the valve stems and
tion.
the socket areas that contact the ends of the push
rods. These areas should be free of damage or
NOTICE: Be careful o f twisting, shearing, or wear.
collapsing the pipe when installing it to the • Rocker arm nuts.
pum p. A dam aged pipe can cause lack o f • Pushrod ends for scoring, roughness, or bends.
lubrication and engine failure. • Roll the pushrod on a flat surface to determine
its straightness. If the rod is bent, the rod will
9. Pickup pipe and screen (57) if removed. not roll freely. Replace if necessary.
A. The pickup pipe and screen assembly should
be replaced with a new part. Loss of press fit HYDRAULIC LIFTERS
condition could result in an air leak and loss of This engine uses hydraulic roller-type lifters.
oil pressure. Hydraulic lifters are serviced only as an assembly. No
B. Mount the oil pump in a soft jawed vise. internal parts are available. Service is limited to a disas
C. Apply sealer to the end of the pipe. sembly and cleaning. It is understood that most techni
D. Tap the pickup screen and pipe into place, cians discard any suspicious valve lifters.
using J 21882 and a hammer.
E. The pump screen must be parallel with the bot 9 Important
tom of the oil pan when installed.
10. Oil pump driveshaft (58) and retainer (64). Whenever the camshaft needs to be replaced, a
new set of hydraulic lifters must also be installed.
VALVE TRAIN COMPONENTS
CYLINDER HEAD DISASSEMBLY
important
Remove or Disconnect (Figures 29 and 30)
• Store all reusable components in an exact order,
so they may be reassembled in the same wear Tool Required:
pattern location from which they were removed. J 8062 Valve Spring Compressor
1. Valve keepers (67).
PUSHRODS, ROCKER ARMS, BALLS, AND NUTS A. Compress the springs with J 8062 (figure 30).
B. Remove the keepers.
C. Remove J 8062.
2. Intake valve components.
All parts in clean solvent and dry them with com A. Cap (68).
pressed air. B. Shield (69).
Make sure the oil passages through the pushrods C. Seal (71).
are clear. D. Damper (72).
E. Spring (73).
V0522
Figure 28— Installing Oil Pump Screen Figure 29—Valves and Components
6A4B-22 4.3L V6 (VIN W)
IJJI Clean
Components as outlined.
L* Inspect
Figure 30—Compressing Valve Springs
Components as outlined.
• Compress the valve spring using J 8062 (figure
m Measure 30), enough so the lower valve stem groove can be
seen clearly.
• Valve stem clearance. 6. O-ring seal (70) onto the valve stem’s lower
• Valve spring tension and free length. groove, making sure the seal (70) is flat and not
Other information outlined includes: twisted.
• Valve and seat grinding. A. Apply a small amount of grease to the area of
• Valve guide reaming. the upper valve stem groove.
ROCKER ARM STUD REPLACEMENT B. Assemble the two valve keepers into the upper
groove using the grease to hold them in place.
+-► Remove or Disconnect C. Release the compressor tool J 8062, making
sure the valve keepers stay in place.
Rocker arm stud by unscrewing. D. Repeat the preceding steps on the remaining
valves.
“►+ Install or Connect
Inspect
NOTICE: Refer to “N otice” on page 6A4B-1.
• O-ring seals for leakage (figure 31).
• Rocker arm stud.
A. Place the suction cup supplied with J 23738-A
Tighten over the shield.
B. Connect J 23738-A to the suction cup and
• Rocker arm stud to 47 N-m (35 lbs. ft.). apply a vacuum.
C. Watch the vacuum pump gage: no air should be
CYLINDER HEAD ASSEMBLY able to leak past the seal.
D. If the seal will not hold a vacuum, it may have
Install or Connect (Figures 29, 30, and 31) been damaged or improperly installed.
E. Repeat the preceding steps on the remaining
Tools Required: valves.
J 8062 Valve Spring Compressor
J 23738-A Valve Stem Seal Tester Measure
1. Valves.
A. Lubricate the valve stems with engine oil. Valve spring installed height of each spring as fol
B. Insert the valves (74 and 76) into the proper lows.
valve guides until the face of the valve contacts 1. Use a narrow thin scale. A cutaway scale may
the valve seat. be helpful.
2. Sea! (71) (intake valve only). 2. From the top of the shim or the bottom of the
A. Install the seal (71) over the valve stem. spring to the top of the shield.
B. Hold the valve (74) against the valve seat. 3. If this measurement exceeds the amount given
C. Push the seal (71) down the valve stem until it in “Engine Specifications,” install valve spring
bottoms out against the head. seat shims approximately 1.6 mm (1/16 inch)
3. Springs (73) and dampers (72). thick (between the spring and cylinder head).
4. Shields (69). NEVER shim the spring so as to give an
5. Cap (68) or rotator (75). installed height under the specified amount.
4.3L V6 (VIN W) 6A4B-23
CRANKSHAFT REAR
OIL SEAL RETAINER
❖ Disassemble
]? Inspect
Install the new crankshaft rear oil seal with the Figure 32—Measuring Crankshaft Journals
proper tool, after the retainer is assembled to the
engine, as outlined later. Flywheel ring gear for worn or broken teeth.
If the flywheel is replaced, new balance weights of
FLYWHEEL the same size must be installed in the same hole
locations as the old flywheel.
1? Inspect
| Clean
Flywheel for burning, scoring, warping, and wear.
Replace the flywheel if necessary. Do not machine Mating surfaces of the crankshaft and flywheel.
the flywheel. Remove any burrs.
$ Tighten
• Gasket surfaces on the block and seal retainer.
• Rear main bearing cap bolts to 14 N-m (124 Install or Connect (Figure 34)
lbs. in.).
1. New gasket (54) to the block.
Measure (Figure 33) • It is not necessary to use sealant to hold the
%
gasket in place.
2. Seal retainer (52).
Crankshaft end play, as follows:
A. Firmly thrust the end of the crankshaft first rear NOTICE: Refer to “iNotice” on page 6A4B-1.
ward then forward. This will line up the rear
main bearing and crankshaft thrust surfaces. 3. Screws (50) and nuts (51).
B. With the crankshaft wedged forward, measure
at the front end of the rear main bearing with a % Tighten
feeler gage (figure 33). The proper clearance is
0.051-0.152 mm (0.005-0.018 inch). • Screws and nuts to 15 N-m (11 lbs. ft.).
C. If correct end play cannot be obtained, be cer
tain that the correct size rear main bearing has CRANKSHAFT REAR OIL
been installed. Production engines may have SEAL INSTALLATION
rear main bearings that are 0.008 inch wider
across the thrust faces than standard. Install or Connect (Figure 35)
A. Rear of Block
50. Screw
51. Nut
52. Retainer
53. Stud
54. Gasket
V0516
A. Feeler Gage V0577
Figure 34—Crankshaft Rear Oil Seal Retainer and
Figure 33— Measuring Crankshaft End Play Components
6A4B-26 4.3L V6 (VIN W)
-►+ Install or Connect (Figures 36 and 37) • Bolts to 14 N-m (124 lbs. in.).
• Coat the camshaft lobes and journals with a high BALANCE SHAFT
quality engine oil supplement (GM Engine Oil Sup INSTALLATION
plement or equivalent)-.
•Apply Engine Oil Supplement (GM P/N 1052367), +4- Install or Connect (Figures 38 and 39)
or equivalent to all the teeth on the distributor drive
gear.
NOTICE: For ste p s 3, 4, and 6, refer to “No
1.Two or three 5/16-18 bolts 100-125 mm (4-5 tice” on page 6A4B-1.
inches) long into the camshaft threaded holes. Use
these bolts to handle the camshaft. Tools Required:
2. Camshaft to the engine (figure 37). Handle the J 38834 Balance Shaft Bearing Service Kit
camshaft carefully to prevent damage to the cam J 36996 Balance Shaft Installer
shaft bearings. J 8092 Driver Handle
J 36660 Torque/Angle Meter
NOTICE: Refer to “N otice” on page 6A4B-1. 1. Balance shaft rear bearing (45) using J 38834 (fig
ure 38).
• Dip bearing in clean engine oil before installa
3. Camshaft retainer and retainer bolts. tion.
2. Balance shaft (47) into block using J 36996 and
J 35621 J 8092.
A. Dip the front balance shaft bearing into clean
engine oil before assembly.
B. Retaining ring on balance shaft front bearing
must be seated on case.
3. Install balance shaft bearing retainer (43) and bolts
(48).
Tighten
a Tighten
34. NUT
35. STUD
36. KEY
37. GEAR, BALANCE SHAFT DRIVE
38. SPROCKET, CRANKSHAFT
39. BOLT
40. SPROCKET CAMSHAFT
41. CHAIN, TIMING
V2629
Important
Tighten
Tighten
3. Torsional damper over the end of the stud. Align FILE RODS OR ROD CAPS. If clearances are exces
the keyway in the torsional damper shaft with the sive, install a new bearing. Service bearings are avail
crankshaft key. able in standard size and 0.0014 mm undersize for use
4. Bearing, washer, and nut. with new and used standard size crankshafts.
A. Turn the nut to pull the vibration damper into
place. •Hr Install or Connect (Figures 42 through 45)
B. Remove the tool.
Tools Required:
NOTICE: Refer to “Notice” on page 6A4B-1. J 5239 Connecting Rod Bolt Guide Set
J 8037 Ring Compressor
5. Torsional damper bolt and washer. J 36660 Torque/Angle Meter
• Lubricate the cylinder walls lightly with engine oil.
$ Tighten • Make sure the piston is installed in the matching
cylinder.
• Bolt to 95 N-m (70 lbs. ft.). 1. Connecting rod bearings.
PISTON AND CONNECTING A. Make sure the bearing inserts are the proper
size.
ROD INSTALLATION B. Install the bearing inserts in the connecting rod
and connecting rod cap.
CONNECTING ROD BEARING SELECTION
C. Lubricate the bearings with engine oil.
Connecting rod bearings are of the precision insert
type and do not use shims for adjustment. DO NOT 2. Piston and connecting rod into the proper bore.
A. With the connecting rod cap removed, install
J 5239 onto the connecting rod bolts (figure
42).
B. Locate the piston ring end gaps (figure 43).
Lubricate the piston and rings with engine oil.
C. Without disturbing the ring end gap location,
install J 8037 over the piston (figure 44).
D. The piston must be installed so that the notch
in the piston faces the front of the engine (fig
ure 44).
o
Q IN G M ilO T ENGINE FRONT ENGINE RIGHT ^
V Important
Measure
V0531
© 0 0 0
_ 0 0 ^ 0 ^
B7874
19. BOLT 21
20. GUIDE ASSEMBLY
21. NUT
22. BALL
23. ARMS, ROCKER
24. PUSHROD
26. LIFTER, HYDRAULIC
3706S2910
Replace all hydraulic lifters, change the engine oil 4. Rocker arms (23) with balls (22) on to the proper
and filter, and add GM Engine Oil Supplement (GM stud.
P/N 1052367) or equivalent to the engine oil when 5. Rocker arm nuts (21) on to the studs.
ever a new camshaft is installed.
• Align the push rod into the rocker arm while
-»4- Install or Connect (Figure 49) tightening rocker arm nut (21).
Important
NOTICE: For ste p s 2 and 5, refer to “Notice”
on page 6A4B-1. No lash adjustment is needed.
Tighten
• Lubricate the hydraulic lifter bodies and feet with
Engine Oil Supplement (GM P/N 1052367) or
equivalent. Rocker arm nuts to 27 N m (20 lbs. ft.).
Figure 50— Lower Intake Manifold Bolt Tightening Figure 51—Upper Intake Manifold Bolt Tightening
Sequence Sequence
Tighten
EXHAUST MANIFOLD
INSTALLATION
♦«- Install or Connect (Figure 53)
1. Exhaust manifold.
2. Heat shield (60).
NOTICE: Refer to “N otice” on page 6A4B-1.
3. Exhaust manifold bolts (63), washers (61), and tab
washers (62).
Tighten
SPECIFICATIONS
ENGINE SPECIFICATIONS (4.3L)
AH S pecifications are in INCHES unless otherw ise noted.
GENERAL DATA:
Type V6
Displacement 4.3L (262 Cu. In.)
RPO (VIN Code) L35 (W)
Bore 4.00
Stroke 3.48
Compression Ratio 9.10:1
Firing Order 1-6-5-4-3-2
Oil Pressure (Minimum Hot) 6 psi @ 1000 RPM; 18 psi @ 2000 RPM; 24 psi @ 4000 RPM
CYLINDER BORE:
Diameter 4.0007-4.0017
Out Of Production 0.001 (Maximum)
Round Service 0.002 (Maximum)
Thrust Side 0.0005 (Maximum)
Production
Taper Relief Side 0.001 (Maximum)
Service 0.001 (Maximum)
PISTON:
Production 0.0007-0.0024
Service Limit 0.0024 (Maximum)
PISTON RING:
C Top
0 Production 0.0014-0.0032
Groove 2nd
M
P Clearance
R Service Limit 0.0042 (Maximum)
E Top
R 0.010-0.020
Production
s 2nd 0.018-0.026
1
0 Service Limit 0.035 (Maximum)
N
Groove Production 0.0014-0.032
0 Clearance Service Limit
1 0.008 (Maximum)
1 Production 0.015-0.055
Service Limit 0.065
PISTON PIN:
Diameter 0.9270-0.9273
Clearance Production 0.0002-0.0007
In Piston Service Lmit 0.001 (Maximum)
Fit In Rod 0.0008-0.0016 Interference
EXHAUST MANIFOLD:
Surface Flatness 0.010 (Maximum)
INLET MANIFOLD:
Surface Flatness 0.010 (Maximum)
CYLINDER HEAD:
Surface Flatness 0.004 (Overall)
BALANCE SHAFT:
Front Bearing Journal Diameter 2.1648-2.1654
Rear Bearing Journal Diameter 1.4994-1.500
Rear Bearing Journal Clearance 0.001-0.0036
T3049
4.3L V6 (VIN W) 6A4B-37
SPECIFICATIONS
ENGINE SPECIFICATIONS (4.3L) (CONT.)
All S pecifications are in INCHES unless otherw ise noted.
DISPLACEMENT: 4.3L (L35, VIN W)
CRANKSHAFT:
#1 2.4488-2.4495
Diameter #2, #3 2.4485-2.4494
#4 2.4480-2.4489
Main
Production 0.0002 (Maximum)
Journal Taper
Service Limit 0.001 (Maximum)
Out Of Production 0.0002 (Maximum)
Round Service Limit 0.001 (Maximum)
#1 0.0008-0.0020
Production #2, #3 0.0011-0.0023
Main #4 0.0017-0.0032
Bearing
Clearance #1 0.0010-0.0015
Service
#2, #3 .0010-0.0025
Limit
#4 0.0025-0.0035
Crankshaft End Play 0.005-0.018
Crankshaft Runout 0.001 (Maximum)
Diameter 2.2487-2.2497
Production 0.0002
Taper
Crankpin Service Limit 0.001 (Maximum)
Out Of Production 0.0002
Round Service Limit 0.001 (Maximum)
Rod Bearing Production 0.0013-0.0035
Clearance Service Limit 0.0030
Rod Side Clearance 0.015-0.046
CAMSHAFT:
Lobe Intake 0.288
Lift ± 0.002 Exhaust 0.294
Journal Diameter 1.8682-1.8692
0.001-0.009
VALVE SYSTEM:
Lifter Hydraulic
Rocker Arm Ratio 1.50:1
Intake
Valve Lash Torque Rocker Arm Nut to 27 N m (20 lbs. ft.)
Exhaust
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) 0.002 (Maximum)
Intake 0.035-0.060
Seat Width
Exhaust 0.062-0.093
Intake 0.0011-0.0027
Production
Stem Exhaust 0.0011-0.0027
Clearance Intake High Limit Production +0.001
Service
Exhaust High Limit Production +0.002
Free Length 2.03
Valve Closed 76-84 lbs. @ 1.70-in.
Pressure
Spring
lbs. @ in. Open 194-206 lbs. @ 1.25-in.
(Outer)
Installed Height ± 1/32" 1.690-1.710
Valve Spring Free Length 1.86
Damper Approx # of Coils 4
Intake 0.432
Valve Lift
Exhaust 0.441
T3050
6A4B-38 4.3L V6 (VIN W)
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Item N-m Lbs. Ft. Lbs. In.
Balance Shaft Drive Gear Retaining Bolt............................. 16 12 —
Balance Shaft Driven Gear Bolt (Torque Plus a 35° Turn), 20 15 —
Balance Shaft Retainer Bolt................................................... 14 — 124
Camshaft Sprocket Bolts......................................................... 28 21 —
Camshaft Thrust Plate Screws............................................... 14 — 124
Connecting Rod Bolt Nuts (Torque Plus 70°)...................... 27 20 —
Coolant Outlet Bolts................................................................. 19 14 —
Coolant Pump Bolts................................................................. 41 30 —
Crankshaft Rear Oil Seal Retainer Screws and Nuts........ 15 11 —
Cylinder Head Bolts (In Sequence)....................................... 90 65 —
EGR Valve Bolt......................................................................... 22 16 —
Engine Block Drain Plug.......................................................... 20 15 —
Exhaust Manifold Bolts
Center Two Bolts.............................................................. 36 26 —
All Others............................................................................ 28 20 —
Flywheel Bolts........................................................................... 100 74 —
Front Cover Bolts...................................................................... 14 — 124
Hydraulic Lifter Guide Assembly Retainer Bolts.................. 16 12 —
Intake Manifold Bolts, Lower (In Sequence)........................ 47 35 —
Intake Manifold Bolts and Studs, Upper (In Sequence)..... 10 — 88
Main Bearing Cap Bolts........................................................... 110 81 —
O I Filter Adapter Bolts................................................... 22 16 —
O I Gallery Plug, Left R ear........................................... 40 30 —
O I Gallery Plug, Right Rear......................................... 40 30 —
O I Gallery Plug, Left Side Rear.................................. 30 22 —
O I Pan Bolts................................................................... 11 — 97
O I Pan Drain Plug......................................................... 25 18 —
O I Pan Nuts.................................................................... 23 17 —
O I Pan Studs to Oil Seal Retainer or Engine Block 23 17 —
O I Pressure Fitting........................................................ 11 — 97
O I Pump Bolt.................................................................. 88 65 —
O I Pump Cover Bolts.................................................... 9 — 80
O I Seal Retainer Studs to Crankcase........................ 47 35 —
Rocker Arm Nuts............................................................ 27 20 —
Rocker Arm Cover Bolts............................................... 10 — 90
Rocker Arm Stud............................................................ 47 35 —
Torsional Damper Bolt.................................................... 95 70 —
T2867
4.3L V6 (VIN W) 6A4B-39
SPECIAL TOOLS
tV .
° g»
1. J 39046 9. J 8001
10 . J 26941
2. J 8062
11.
J 24270
4. J 8080 J 5825-A
13.
6. J 5239
15. J 35621
16. J 8092
J 23738-A
7.
17. J 36996
8.
V*
S3XON
......... ................
(M NIA) 9A l £ ‘t 0 t-a frV 9
V8 ENGINES 6A5B-1
SECTION 6A5B
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
CAUTION: On vehicles equipped with Supplemental Inflatable Restraint (SIR), refer to CAUTIONS in
Section 9J under “ON-VEHICLE SERVICE” and the SIR Component and Wiring Location view in Section
9J before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could
result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs.
NOTICE: Always use the correct fastener in the correct location. Use the correct fastener part num ber to
replace a fastener. If the correct fastener part num ber is not available, a fastener o f equal size and
strength m ay be used. Do n ot u se a fastener that is stronger when the correct fastener part num ber is not
available in the following applications:
• Som e bolts are designed to permanently stretch, and if a stronger fastener is used, the part will not be
tightened correctly. These permanently stretching bolts will be called out. The correct part number
fasteners m u st be used to replace this type o f fastener because there is no available equivalent.
• Other bolts are designed to break if over tightened to prevent part damage. Using a stronger fastener
may cause part damage to occur. Fasteners that need to be replaced when removed will be called out.
The correct tightening specification and sequence m ust be used when installing fasteners. Part or system
damage m ay occur if the above instructions are not followed.
CONTENTS
SUBJECT PAGE
General Description............................................................................................................................................... 6A5B- 3
Engine Identification.......................................................................................................................................... 6A5B- 3
Disassembly of the Engine...................................................................................................................................6A5B-13
Tools and Shop Equipment..............................................................................................................................6A5B-13
Accessory Removal............................................................................................................................................ 6A5B-13
Cleaning................................................................................................................................................................ 6A5B-13
Draining the Engine........................................................................................................................................... 6A5B-13
Exhaust Manifold Removal............................................................................................................................... 6A5B-14
Coolant Pump Removal.....................................................................................................................................6A5B-14
Intake Manifold Removal...................................................................................................................................6A5B-14
Rocker Arm Cover Removal............................................................................................................................ 6A5B-14
Valve Train Component Removal............................................. ...................................................................... 6A5B-14
Cylinder Head Removal.....................................................................................................................................6A5B-16
Torsional Damper Removal.............................................................................................................................. 6A5B-16
Oil Pan Removal................................................................................................................................................. 6A5B-16
Oil Pump Removal.............................................................................................................................................. 6A5B-16
Front Cover Removal.........................................................................................................................................6A5B-17
Timing Chain and Camshaft Sprocket Removal.........................................................................................6A5B-17
Camshaft Removal............................................................................................................................................. 6A5B-17
Piston and Connecting Rod Removal........................................................................................................... 6A5B-19
Flywheel Removal............................................................................................................................................... 6A5B-21
Crankshaft Rear Oil Seal Retainer Removal (5.0L and 5.7L Engines)................................................. 6A5B-21
Crankshaft Removal...........................................................................................................................................6A5B-21
Cleaning, Inspection, and Repair........................................................................................................................6A5B-25
Cylinder Block..................................................................................................................................................... 6A5B-26
Main Bearing Cap Replacement................................... ............................................................................. 6A5B-28
Cylinder Bores...................................... .......................................................................................................... 6A5B-28
Piston and Connecting Rod Assemblies......................................................................................................6A5B-28
6A5B-2 V8 ENGINES
CONTENTS (cont’d)
SUBJECT PAGE
Piston Selection..............................................................................................................................................6A5B-28
Intake and Exhaust Manifold...........................................................................................................................6A5B-29
Camshaft............................................................................................................................................................... 6A5B-29
Camshaft Bearings.............................................................................................................................................6A5B-29
Timing Chain and Sprockets...........................................................................................................................6A5B-29
Crankshaft Sprocket Replacement............................................................................................................. 6A5B-30
Front C over..........................................................................................................................................................6A5B-30
Coolant Pum p..................................................................................................................................................... 6A5B-31
Oil Pan and Rocker Arm C overs................................................................................................................... 6A5B-31
Oil Pump.............................................................................. .................................................................................6A5B-31
Valve Train Components................................................................................................................................... 6A5B-33
Pushrods, Rocker Arms, Balls, and N uts................................................................................................ 6A5B-33
Hydraulic Lifters.............................................................................................................................................. 6A5B-33
Cylinder Head.......................................................................................................................................................6A5B-33
Disassembly......................................................................................................................................................6A5B-33
Cleaning and Inspection............................................................................................................................... 6A5B-34
Rocker Arm Stud Replacement (5.0L and 5.7L Engines).................................................................... 6A5B-34
Assembly (5.0L and 5.7L Engines).............................................................................................................6A5B-34
Assembly (7.4L Engines).............................................................................................................................. 6A5B-36
Thermostat and Coolant Outlet.......................................................................................................................6A5B-36
Torsional Dam per............................................................................................................................................... 6A5B-37
Crankshaft and Bearings.................................................................................................................................. 6A5B-37
Crankshaft Rear Oil Seal Retainer (5.0L and 5.7L Engines)................................................................... 6A5B-38
Assembly of the Engine....................................................................................................................................... 6A5B-38
Prior to Assembly............................................................................................................................................... 6A5B-38
Crankshaft and Main Bearing Installation.................................................................................................... 6A5B-38
Undersize Main Journals (5.0L and 5.7L Engines)................................................................................ 6A5B-38
Oversize Rear Main Bearing Thrust Faces (5.0L and 5.7L Engines)................................................ 6A5B-38
Crankshaft Rear Oil Seal Installation (7.4L Engines)................................................................................ 6A5B-40
Crankshaft Rear Oil Seal and Retainer Installation (5.0L and 5.7L Engines).................................... 6A5B-40
Camshaft, Timing Chain, and Sprocket Installation.................................................................................. 6A5B-41
Front Cover Installation.................................................................................................................................... 6A5B-42
Torsional Damper Installation..........................................................................................................................6A5B-42
Piston and Connecting Rod Installation...................................................................................................... 6A5B-42
Connecting Rod Bearing Selection............................................................................................................6A5B-42
Oil Pump Installation..........................................................................................................................................6A5B-44
Oil Pan Installation............................................................................................................................................. 6A5B-44
5.0L and 5.7L Engines.................................................................................................................................. 6A5B-44
7.4L Engines.................................................................................................................................................... 6A5B-45
Cylinder Head Installation................................................................................................................................ 6A5B-45
Valve Train Component installation............................................................................................................... 6A5B-46
Valve Adjustment................................................................................................................................................ 6A5B-46
5.0L and 5.7L Engines.................................................................................................................................. 6A5B-46
Intake Manifold Installation.............................................................................................................................. 6A5B-48
5.0L and 5.7L Engines.................................................................................................................................. 6A5B-48
7.4L Engines.................................................................................................................................................... 6A5B-48
Rocker Arm Cover Installation........................................................................................................................6A5B-49
Exhaust Manifold Installation...........................................................................................................................6A5B-50
Coolant Pump Installation................................................................................................................................ 6A5B-50
Flywheel Installation...........................................................................................................................................6A5B-51
Engine Accessory Installation.........................................................................................................................6A5B-52
Engine Set-Up and Testing.............................................................................................................................. 6A5B-53
Specifications..........................................................................................................................................................6A5B-54
Engine Specifications (5.0L and 5.7L Engines)..........................................................................................6A5B-54
Engine Specifications (7.4L Engines)............................................................................................................6A5B-56
Fastener Tightening Specifications (5.0L and 5.7L Engines)................................................................. 6A5B-58
Fastener Tightening Specifications (7.4L Engines)................................................................................... 6A5B-58
Special Tools...........................................................................................................................................................6A5B-59
V8 ENGINES 6A5B-3
GENERAL DESCRIPTION
The engines covered in this section are 90-degree V8 surized oil is delivered through internal passages to the
type, overhead valve, liquid cooled, with cast iron block camshaft and crankshaft to lubricate the bearings. Oil
and cylinder heads. under pressure flows from the hydraulic lifters through
The camshaft is supported by five plain type bearings the pushrod to lubricate the rocker arm and ball pivot.
and is chain driven. Motion from the camshaft is trans This provides valve lash take-up from the lifters. Lubri
mitted to the valves by hydraulic lifters, pushrods, and cation diagrams are shown in figures 1, 2, and 3.
ball-pivot type rocker arms. Heavy Duty 5.7L exhaust
valve guides and all 7.4L valve guides are pressed in. ENGINE IDENTIFICATION
The crankshaft is supported by five precision insert Two basic types of engines, with three different dis
type bearings, with crankshaft thrust taken at the num placements, are covered in this section.
ber five (rear) bearing. The first type is the “small block” engine, which is
The connecting rods are forged steel, with precision available in 5.0L (305 CID) and 5.7L (350 CID) dis
insert type crankpin bearings. The piston pins are a
placements.
press fit in the connecting rods. The second type is the 7.4L (454 CID) engine, which
The pistons are cast aluminum alloy. The piston pins
is sometimes referred to as the “Mark” engine.
are a floating fit in the pistons.
To determine the displacement of the engine, use the
The gear-type oil pump is driven through an exten
vehicle identification number (VIN) of the vehicle the
sion shaft from the distributor driveshaft which is gear
engine was removed from. Refer to “Engine Specifica
driven from the camshaft. The oil is drawn from the
tions” at the end of this section. If the VIN is not avail-
engine oil pan through a pickup screen and tube. Pres
F9474
3706S3004
A. To Oil Cooler
B. From Oil Cooler
C. From Oil Pump
D. Camshaft Bearings
E. Valve Lifters
F. Oil Filter
G. Oil Cooler Diverter
H. Main Bearings
I. Oil Cooler Bypass Valve
J. Oil Filter Bypass Valve
F9477
able, the bore and stroke of the engine involved can be Refer to Section OA in the proper on-vehicle Truck
measured and compared against “Engine Specifica Service Manual identification information. Refer to fig
tions” to determine the engine model; or, with “Mark” ures 4 through 11 for engine component identification.
engines, the engine displacement (in liters) is cast into
each side of the cylinder block.
6A5B-6 V8 ENGINES
3706S3003
Figure 5—Cylinder Block and Components (5.0L and 5.7L Engines) - Legend
6A5B-8 V8 ENGINES
20 2 \ 302
v 41 —
250 251 ___ _
251
^ 5 4 ^ r r 39
A 252 ®-«— 252
<SU-255 ©>*— 255
210 # -*-2 5 6 # -* — 256
201
205
_ ^206
208 207
v
X * <>>
209
^^3
V1196
Figure 6—Cylinder Head, Manifolds, and Components (5.0L and 5.7L Engines)
V8 ENGINES 6A5B-9
1. Exhaust Manifold
2. Washer 202. Spark Plug
3. Exhaust Manifold Lock 205. Plug
4. Bolt/Stud 206. Spark Plug Wire Support
6. Heat Shield 207. Air Injection Pipe Extension
7. Outer Heat Stove 208. Dowel Pin
8. Inner Heat Stove 209. Valve Lifter
20. Bolt/Stud 210. Pushrod
21. Intake Manifold 211. Spark Plug Wire Retainer Support
22. Intake Manifold Gasket 212. Drain Plug
32. Rocker Arm Cover 213. Coolant Temperature Sensor
34. Rocker Arm Cover Gasket 250. Rocker Arm Stud
36. Rocker Arm Cover Bolt 251. Valve Stem Key
39. Inlet Valve Spring Cap 252. Valve Stem Oil Seal (O-Ring)
40. Rocker Arm Nut 254. Exhaust Valve Rotator
41. Rocker Arm Ball 255. Valve Stem Oil Shield
42. Rocker Arm 256. Valve Spring with Damper
46. Cylinder Head 257. Valve Stem Oil Seal
47. Cylinder Head Gasket 258. Exhaust Valve
50. Plug 259. Inlet Valve
51. Cylinder Head Bolts 300. Bolt/Stud
200. Oil Filler Cap 301. Coolant Outlet
201. Spark Plug Wire Retainer Support 302. Gasket
303. Thermostat
V1197
Figure 7—Cylinder Head, Manifolds, and Components (5.0L and 5.7L Engines) - Legend
6A5B-10 V8 ENGINES
100
187
r Jn
185 183 177
*v \
75 201
3706r1204
V1205
3706S3006
3706S3006
1. Exhaust Manifold
2. Washer
3. Lock
4. Bolt/Stud
6. Spark Plug Wire Heat Shield
3. Block drain plugs. Allow the coolant to drain. 2. Coolant pump (10).
3. Gaskets (11).
■H" Install or Connect 4. Bypass hose and clamps (7.4L engines).
1 EXHAUST M AN IFO LD
4 B O L T /S T U D
6 SPARK P LU G HEAT S H IE L D
3706S30G5
1. Bolts (45 or 51). 1. Oil pan bolts (72 or 75), nuts (73, 5.0L and 5.7L
2. Cylinder heads (46). Use care when handling the only), and clips.
cylinder heads, to prevent damage to the gasket 2. Oil pan (71 or 76).
sealing surfaces. 3. Gasket (74).
3. Gaskets (47). 4. Oil pan deflector nuts (76) (figure 29).
1. Crankshaft pulley.
2. Torsional damper retaining bolt and washer.
3. Torsional damper. Use J 39046 (figure 27).
V8 ENGINES 6A5B-17
A S E A LIN G COM PO U N D
21 INTAKE M A N IFO LD
22 GASKET
23 SEAL
3706S3008
1. Bolts (93).
2. Front cover (91).
3. Gasket (90).
CAMSHAFT REMOVAL
Remove or Disconnect (Figure 33)
32. Rocker Arm Cover
34. Gasket
• Camshaft.
36. Bolt
A. Install three 5/16-18 bolts 100-125 mm (4-5
F9362 inches) long into the camshaft tapped holes.
Use these bolts to handle the camshaft.
Figure 18— Rocker Arm Cover (5.0L and 5.7L B. Pull the camshaft from the block.
Engines) C. Use care to prevent damage to the camshaft
and bearings.
6A5B-18 V8 ENGINES
30
32 R O C KER ARM COVER
3706S3013
V2880
Tool Required:
J 5239 Connecting Rod Guide Set
1. Ridge (or deposits) at the top of the cylinder as
follows:
A. Turn the crankshaft until one piston is at the
bottom of its stroke. Place a soft cloth on top of
the piston.
B. Using the manufacturer’s directions, install a
ridge reamer into the top of the cylinder (figure
34). Perform the cutting operation.
47 C. After the ridge and/or deposits are removed,
remove the ridge reamer. Turn the crankshaft
until the piston is at the top of its stroke.
Remove the cloth and cuttings.
D. Repeat this procedure for each piston.
2. Connecting rod caps as follows:
A. Make note of the arrangement of the connect
45. Bolt ing rod markings, to ensure they will be
46. Cylinder Head returned to their proper position during assem
47. Gasket bly. Mark the connecting rods with a scratch awl
if necessary.
F9327 B. Remove the connecting rod bolt nuts.
C. To avoid mismatching the connecting rods and
Figure 21—Cylinder Head (7.4L Engines) connecting rod caps, remove only one connect
ing rod cap at a time. Place the piston at the
bottom of its stroke.
V2881
40. Bolt
41. Ball
42. Rocker Arm
43. Pushrod
44. Hydraulic Lifter
46. Cylinder Head
260. Pushrod Guide
F9325
-B-
6o G
o o
-C
o o
0
o O
o o o O
o o o O
o o o \
o o o
o o o o
FRONT
Figure 25—Removing the Hydraulic Lifter
70 P U M P , OIL
71 P AN , OIL
72 B O LTS (S T U D S IF U S E D )
73 NUT
74 GASKET
75 R E IN FO R C E M E N T
3706S3002
Figure 27—Removing the Torsional Damper Figure 28—Oil Pan (5.0L and 5.7L Engines)
B. Use the guide rod to prevent the connecting rod CRANKSHAFT REMOVAL
from scoring the cylinder bore.
C. Install the connecting rod cap onto the connect ++ Remove or Disconnect (Figure 39)
ing rod. Do not tighten.
D. Repeat this procedure on the remaining piston • Check the main bearing caps for location markings.
and connecting rod assemblies. Mark the caps if necessary. The caps must be
returned to their original locations with the orienta
FLYWHEEL REMOVAL tion arrow pointing forward during assembly.
1. Bolts (134).
Remove or Disconnect (Figures 36 and 37)
2. Main bearing caps (132 and 133).
3. Crankshaft. Lift the crankshaft straight up. Use care
1. Bolts (111).
to avoid damage to the crankshaft journals and
2. Flywheel (110A or 11 OB).
thrust flange surfaces.
4. Rear seal (131).
CRANKSHAFT REAR OIL 5. Main bearing inserts (135 and 136). If the main
SEAL RETAINER REMOVAL bearings are to be reused, mark them to ensure
(5.0L and 5.7L ENGINES) they are installed in their original positions before
removal.
Remove or Disconnect (Figure 38)
A. Sealing Compound
74. Gasket
75. Bolt
76. Oil Pan
F9331
A. 16 m m
(5/s-inch)
Maximum -
.
100 Bolt
101. Camshaft Sprocket
102. Timing Chain B8012 B5065
Figure 32—Timing Chain and Sprockets Figure 34— Removing the Cylinder Ridge
M 0303
B0515
Figure 33—Removing the Camshaft Figure 35—Removing the Piston and Connecting
Rod
■'i
6A5B-24 V8 ENGINES
A. WEIGHT
110A. FLYWHEEL (MANUAL TRANSMISSION) 111
110B. FLYWHEEL (AUTOMATIC TRANSMISSION)
111. BOLT, FLYWHEEL
168. PIN. FLYWHEEL DOWEL
V2878
Figure 38—Crankshaft Rear Oil Seal Retainer (5.0L and 5.7L Engines)
V8 ENGINES 6A5B-25
133 134
130. C rankshaft
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
V2883
Figure 40—Engine Block Oil Gallery Hole Plugs (5.0L and 5.7L Engines)
CYLINDER BLOCK
Clean (Figures 40, 41, and 42)
Disassemble 175
144. BLOCK, ENGINE 144
• Cooling jacket plugs. 175. PLUG, ENGINE BLOCK COOLANT DRAIN HOLE
1. Obtain a suitable self-threading screw.
2. Drill a hole into the plug. V2879
3. Install the self-threading screw.
Figure 41—Engine Block Coolant Drain Hole Plug
4. Remove jacket plugs. (5.0L and 5.7L Engines)
• Oil gallery screw plugs.
]P Inspect
Clean (Figures 40, 41, and 42)
1. All expansion plugs for poor fit or leakage.
• Sealing material from mating surfaces. 2. Hydraulic lifter bores for deep scratches and var
• Boil cylinder block in caustic solution. nish deposits.
— Flush with clean water or steam. 3. Block for cracks.
• Cylinder bores. • Cylinder walls.
• Oil galleries and passages (figures 40 and 42). • Coolant jackets.
• Scale deposits from the coolant passages. • Main bearing webs.
• Spray or wipe cylinder bores and machined sur • Engine mount bosses.
faces with engine oil. 4. Main bearing bores and main bearing caps.
V8 ENGINES 6A5B-27
227
224
223 a- 210
210. PLUG, ENGINE BLOCK COOLANT DRAIN
220. PLUG, OIL FEED HOLE
222 221. 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. PLUG, OIL GALLERY HOLE
V2888
Figure 42—Engine Block Oil Gallery Hole and Coolant Drain Hole Plugs (7.4L Engines)
CYLINDER BORES
I? Inspect
Measure
Measure Important
Main bearing vertical ID (inside diameter). Use
• Measure piston diameter at 20° C (70° F).
an inside micrometer.
This dimension should be the same as the oth C. Subtract the piston diameter from the cylinder
er main bearing bore vertical diameters. bore diameter to determine piston to bore clear
ance.
D. Locate the piston to bore clearance refer to
“Engine Specifications.” Determine if the piston
to bore clearance is in the acceptable range.
Important
CAMSHAFT
Important
I? Inspect
Tool Required:
J 7872 Dial Indicator (or equivalent)
• Camshaft runout (figure 47). Mount the camshaft in
V-blocks or between centers. Using J 7872, check
Figure 48—Checking the Camshaft Journals the intermediate camshaft journal. If runout on
5.0/5.7L engines exceeds 0.0254 mm (0.002 inch)
IjJ Measure and on 7.4L engines 0.0635 mm (0.0025 inch), the
camshaft is excessively bent and should be
Ring end gap and ring clearance. Refer to Section replaced along with the camshaft bearings.
6A. • Camshaft journal out-of-round. Use a micrometer
(figure 46). If the journals are more than 0.00254
L* Inspect mm (0.001 inch) out-of-round, replace the cam
shaft.
Ring fit. Refer to Section 6A. • Camshaft journal diameter. Use a micrometer (fig
ure 48). The proper diameter is listed in “Engine
INTAKE AND EXHAUST Specifications.”
Old pieces of gasket from the gasket surfaces. TIM IN G CHAIN AND
Excessive carbon build-up in the exhaust passages
of the intake manifold. SPROCKETS
Scale and deposits from the coolant passages of
the intake manifold. I9 Inspect
EGR passage (if used) of excessive carbon depos
its. Sprockets for chipped teeth and wear.
Timing chain for damage.
I f Inspect (Figure 46) It should be noted that excessively worn sprockets
will rapidly wear a new chain. Likewise, an exces
Manifolds for cracks, broken flanges, and gasket sively worn chain will rapidly wear a new set of
surface damage. sprockets.
6A5B-30 V8 ENGINES
Figure 49—Crankshaft Sprocket Replacement (5.0L Figure 50—Crankshaft Sprocket Replacement (7.4L
and 5.7L Engines) Engines)
CRANKSHAFT SPROCKET REPLACEMENT FRONT COVER
* Disassemble (Figures 49 and 50)
XJJjR Clean
Tools Required:
J 5825 Crankshaft Sprocket Puller • Old gasket from the gasket surfaces.
J 28509-A Crankshaft Sprocket Puller
Inspect
1. Crankshaft sprocket. On 5.0L and 5.7L engines,
use J 5825 (figure 49). On 7.4L engines, use
J 28509-A (figure 50). Timing marker for damage.
2. Key, if necessary. Front cover for damage, dents, or cracks.
Tools Required: Crankshaft front seal. Pry the seal out with a
J 5590 Crankshaft Sprocket Installer screwdriver. If the front cover is off the engine,
J 22102 Crankshaft Sprocket Installer push the seal out by hitting it with a screwdriver
1. Key, if removed. from the inside of the cover to the outside.
2. Crankshaft sprocket. Use J 5590 (5.0L and 5.7L
engines) or J 22102 (7.4L engines). Make sure the
timing mark faces outside.
V8 ENGINES 6A5B-31
* Assemble
COOLANT PUMP
Clean
m a n e n tly lu b ric a ted b ea rin g s a n d c a u s e Figure 51—Installing the Crankshaft Front Seal
premature bearing failure.
6. Spring retaining pin (185).
|y | Inspect 7. Spring (184).
8. Pressure relief valve (183).
• Coolant pump shaft for rotation and end play. The 9. Pickup screen and pipe (187).
shaft and fan hub should turn straight and smooth
ly. If the hub wobbles or the shaft is noisy or feels • Do not remove the pickup screen and pipe
“lumpy” when turned, replace the coolant pump. If unless replacement is required. The 7.4L
the shaft end play exceeds 0.381 mm (0.015 inch), engine uses a pickup pipe and screen that are
replace the coolant pump. welded to the oil pump assembly and must be
• Coolant pump body at the drain (weep) hole. Slight ground off for replacement.
staining around the weep hole is normal. Replace • The pickup pipe is press fit in the pump body to
the coolant pump only if coolant is dripping from seal it and welded to retain it (7.4L engines
the weep hole while the engine is running or while only).
the system is pressurized. • Do not try to remove the screen from the pipe.
The pickup screen and pipe are only serviced
OIL PAN AND ROCKER ARM as an assembly.
COVERS
Clean
|y | Clean
• All parts in clean solvent and blow dry with com
• Parts in solvent. Remove all sludge and varnish. pressed air.
• Old gaskets from the gasket surfaces.
L* Inspect 179
180
Gasket flanges for bending or damage.
Rubber grommets and parts on the rocker arm cov 178
er for deterioration.
Oil pan for rock damage or cracks.
178. Oil Pump Driveshaft
Oil pan deflector for lack of fit.
Drain plug threads for stripping. 179. Connector 188
180. Body
OIL PUMP 181. Drive Gear and Shaft 187
182. Cover
Disassemble (Figures 52 and 53) 183. Pressure Relief Valve
❖ 184. Spring
1. Oil pump driveshaft (178) and connector (179). 185. Spring Retaining Pin
2. Cover screws (186). 186. Cover Screws
3. Cover (182) and gasket (190) (7.4L engines). 187. Pick-up Screen and Pipe
• Mark the gear teeth so the pump gears can be 188. Idler Gear B8020
installed with the same gear teeth indexed.
4. Drive gear and shaft (181). Figure 52—Oil Pump Components (5.0L and 5.7L
5. Idler gear (188). Engines)
6A5B-32 V8 ENGINES
Tool Required:
J 21882 Pickup Tube and Screen Installer
(5.0L and 5.7L engines)
1. Pressure relief valve (183).
2. Spring (184).
3. Spring retaining pin (185).
4. Drive gear and shaft (181).
178 OIL PUMP DRIVESHAFT 5. Idler gear (188) in the pump body (180) with the
179 CONNECTOR smooth side of the gear toward the pump cover
180 BODY 182 opening. Index the marks made during disassem
186
181 DRIVE GEAR AND SHAFT bly.
182 COVER
183 PRESSURE RELIEF VALVE
NOTICE: Refer to “N otice” on page 6A5B-1.
184 SPRING
185 SPRING RETAINING PIN
186 COVER SCREWS 6. Cover (182), gasket (190) (7.4L engines), and
187 P IC K -U P SCREEN AND PIPE screws (186).
188 IDLER GEAR
190 GASKET 3806S3065 a Tighten
Figure 54— Installing the Oil Pump Pickup Tube and Screen (5.0L and 5.7L Engines)
V8 ENGINES 6A5B-33
Pyj Clean
CYLINDER HEAD
DISASSEMBLY
* Disassemble (Figures 55, 56, and 57) 40. Nut 253. Cap
41. Ball 254. Rotator
Tool Required: 42. Rocker Arm 255. Shield
J 8062 Valve Spring Compressor 46. Cylinder Head 256. Spring
1. Valve keepers (251). 47. Gasket with Damper
A. Compress the springs (256) with J 8062 (figure
250. Rocker Arm Stud 257. Seal
57).
251. Valve Keeper 258. Exhaust Valve
B. Remove the valve keepers (251).
252. O-Ring Seal 259. Intake Valve
C. Remove J 8062.
2. Caps (253), shields (255), springs with dampers
(256), and rotators (254). F9470
3. O-ring seals (252) (if used) and seals (257).
4. Valves (258 and 259). Place them in a rack so they Figure 55—Cylinder Head and Components (5.0L
can be returned to their original position at assem and 5.7L Engines)
bly.
6A5B-34 V8 ENGINES
40
41 ^
A. Nut
B. Flat Washer L0620
J 23738-A
1. Bolts (24) or studs (20). Figure 64—Thermostat and Components (5.0L and
2. Coolant outlet (21). 5.7L Engines)
V8 ENGINES 6A5B-37
I? Inspect
Tighten
TORSIONAL DAMPER
1? Inspect
3706S3009
Figure 67—Checking Crankshaft Run-Out Figure 68—Seal Removal Notches (5.0 and 5.7L
Engines)
Crankshaft Bearing Availability
Crankshaft main and connecting rod bearings are Clean
available in 0.0254 mm (0.001 inch), 0.0508 mm (0.002
inch), 0.2540 mm (0.010 inch), and 0.5080 mm All traces of old gasket from the retainer.
(0.020-inch) undersizes.
I? Inspect
CRANKSHAFT REAR
OIL SEAL RETAINER Retainer for cracks, porosity, and damage to the
sealing surfaces.
(5.0L AND 5.7L ENGINES)
Important
* Disassemble (Figure 68)
Crankshaft rear oil seal. Insert a screwdriver into Install the new crankshaft rear oil seal with the
the notches provided in the seal retainer and pry proper tool after the retainer is assembled to the
the seal out (figure 68). engine, as outlined later.
133 134
135
Tighten
• Main bearing cap bolts to specifications.
Tool Required:
J 38841 Seal Installer
• Crankshaft rear oil seal.
A. Make sure the crankshaft rear chamfer is free
of grit, loose rust, and burrs. Correct as needed.
B. Lubricate the inner and outer diameter of the
seal with engine oil.
C. Install the seal on J 38841.
D. Position J 38841 against the crankshaft. Thread
B. With the crankshaft wedged forward, measure the attaching screws into the tapped holes in
at the front end of the rear main bearing with a the crankshaft.
feeler gage (figure 71). The proper clearance is E. Tighten the screws securely with a screwdriver.
0.0508-0.1524 mm (0.002-0.006-inch) (5.0L and This will ensure the seal is installed squarely
5 . 7 L e n g i n e s ) or 0 . 0 5 0 8 - 0 . 2 5 4 0 mm over the crankshaft.
(0.002-0.010-inch) (7.4L engines). F. Turn the handle until it bottoms.
C. On 5.0L and 5.7L engines, if correct end play G. Remove J 38841.
cannot be obtained, make sure the correct size
rear main bearing has been installed. Produc CRANKSHAFT REAR OIL SEAL
tion engines may have rear main bearings that AND RETAINER INSTALLATION
are 0.2032 mm (0.008 inch) wider across the
thrust faces than standard, as explained previ
(5.0L AND 5.7L ENGINES)
ously. -►4- Install or Connect (Figures 72 and 73)
L1 Inspect
Tool Required:
J 35621 Seal Installer
Crankshaft for binding. Try turning the crankshaft to • Whenever the seal retainer is removed, a new
check for binding. If the crankshaft does not turn retainer gasket and crankshaft rear oil seal must be
freely, loosen the main bearing cap bolts on one installed.
cap at a time until the tight bearing is located. 1. Gasket (84) to the block. It is not necessary to use
Burrs on the bearing cap, foreign matter between sealant to hold the gasket in place.
the insert and the block or the bearing cap, or a 2. Seal retainer (82).
Figure 72—Crankshaft Rear Oil Seal Retainer (5.0L and 5.7L Engines)
V8 ENGINES 6A5B-41
Measure
$ Tighten
Important
Bolts (93) to specifications: 2. Stud (item A, figure 77) to the crankshaft. Thread
the stud fully into the tapped hole in the crankshaft.
— 5.0L and 5.7L engines: 11 N-m (97 lbs. in.). 3. Torsional damper over the end of the stud. Align
— 7.4L engines: 11 N-m (97 lbs. in.). the keyway in the torsional damper shaft with the
crankshaft key.
• Use a small amount of RTV sealant to seal the
keyway to crankshaft joint.
4. Bearing, washer, and nut (figure 77).
A. Turn the nut to pull the torsional damper into
place.
B. Remove the tool.
Tighten
• Bolt to specifications.
90. Gasket — 5.0L and 5.7L engines: 95 N-m (70 lbs. ft.).
91. Front Cover — 7.4L engines: 149 N-m (110 lbs. ft.).
93. Bolt F9357
PISTON AND CONNECTING
Figure 76—Front Cover
ROD INSTALLATION
CONNECTING ROD BEARING SELECTION
Connecting rod bearings are the precision insert type
and do not use shims for adjustment. DO NOT FILE
RODS OR ROD CAPS. If clearances are excessive,
install a new bearing. Service bearings are available in
standard size and 0. 0254- mm (0.001-in ch ) and
0.0508-mm (0.002-inch) undersize for use with new and
used standard size crankshafts, and in 0.2540-mm
(0.010-inch) and 0.020-inch undersize for use with
reconditioned crankshafts.
On production 5.0L and 5.7L engines, it is possible to
find a 0.2540-mm (0.010-inch) undersize bearing.
These are used in manufacturing for selective fitting.
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 standard insert
with one half of a 0.2504-mm (0.001-inch) undersize
insert which will decrease the clearance 0.0127 mm
(0.0005-inch) from using a full standard bearing.
V8 ENGINES 6A5B-43
Tools Required:
J 5239 Connecting Rod Guide Set
J 8037 Ring Compressor
• Lubricate the cylinder walls lightly with engine oil.
• Make sure the piston is installed in its matching
cylinder.
1. Connecting rod bearing inserts.
A. Make sure the inserts are the proper size.
B. Install the inserts in the connecting rod and
connecting rod cap.
2. Piston and connecting rod to the proper bore.
A. With the connecting rod cap removed, install
J 5239 onto the connecting rod bolts.
B. Locate the piston ring end gaps as shown in
figure 78 (5.0L and 5.7L engines) or figure 79
(7.4L engines).
C. Lubricate the piston and rings with engine oil.
D. Without disturbing the ring end gap location,
install J 8037 over the piston (figure 80). and 5.7L Engines)
E. Use a hammer handle to tap the piston down
into its matching bore.
• On 5.0L and 5.7L engines, the notch in the
piston crown (figure 78) must face the front
of the engine.
• On 7.4L engines, the dimple must face the
front of the block (figure 81).
F. While tapping the piston into its bore, guide the
connecting rod into position on the crankpin,
using J 5239. Hold the ring compressor against
the block until all rings have entered the cylin
der bore.
Important
Measure
£ Tighten
70 P U M P , OIL
71 PAN , OIL
72 B O LT S (S T U D S IF U S E D )
73 NUT
74 GASKET
75 R EIN FO R C E M E N T
Figure 82—Measuring Connecting Rod Side
Clearance
3706S3002
Measure (Figure 82)
Figure 83—Oil Pan (5.0L and 5.7L Engines)
Connecting rod side clearance. Use a feeler gage
between the connecting rods (figure 82). The prop
er clearance is as follows:
OIL PAN INSTALLATION
— 5.0L and 5.7L engines: 0.1524 -0 .3556-mm 5.0L AND 5.7L ENGINES
(0.006-0.014-inch).
— 7.4L engines: 0 .3 3 0 2 - 0 .5842-mm +*• Install or Connect (Figures 83 and 84)
(0.013-0.023-inch).
•Apply RTV sealer (GM P/N 12346141) or equiva
OIL PUMP INSTALLATION lent to the front cover to block joint and crankshaft
rear seal retainer to block joint.
-►4- Install or Connect 1. Oil pan gasket (74) to the oil pan (71).
2. Oil pan deflector nuts (76) (figure 84).
1. Oil pump with connector and oil pump driveshaft. 3. Oil pan (71) to the engine.
4. Oil pan bolts (72), nuts (73), and reinforcements
(75).
NOTICE: Refer to “N otice” on page 6A5B-1.
Tighten
2. Oil pump to main bearing cap bolt.
• Oil pan bolts (72) to 11 N-m (97 lbs. in.).
£ Tighten • Oil pan nuts (73) to 22 N-m (16 lbs. ft.).
• Oil pan deflector nuts (76) to 36 N-m (27 lbs.
Bolt to 90 N m (65 lbs. ft.). ft.).
V8 ENGINES 6A5B-45
Tighten Tighten
• Bolts to 22 N-m (16 lbs. ft.). Bolts in three steps using the sequence shown
in figures 90 or 91 until the proper torque is
CYLINDER HEAD INSTALLATION reached:
— 5.0L and 5.7L engines:
HP Clean A. The first sequence to 35 N-m (25 lbs. ft.).
B. The second sequence to 60 N-m (45 ft.
• Gasket surfaces on block and cylinder head. lbs).
C. The final torque sequence to 90 N-m (65
-¥+ Install or Connect (Figures 86 through 91) lbs. ft.).
— 7.4L engines:
1. Head gasket. A. The first sequence to 40 N-m (30 lbs. ft.).
• Use no sealer on engines using a composition B. The second sequence to 80 N-m (60 ft.
gasket. lbs).
• Place the gasket in position over the dowel pins C. The final torque sequence to 115 N-m
with the bead up. (85 lbs. ft.).
6A5B-46 V8 ENGINES
VALVE TRAIN COMPONENT • Lubricate the feet of the lifters with “Moly Kote.”
Q , Tighten
Adjust
VALVE ADJUSTMENT
5.0L and 5.7L ENGINES
1. Remove the rocker arm covers.
45. Bolt 2. Crank the engine until the mark on the torsional
46. Cylinder Head damper lines up with the center or “0” mark on the
47. Gasket
timing tab (figure 92). The engine must be in the
number one firing position. This may be determined
F9327 by placing fingers on the number one cylinder’s
valves as the mark on the damper comes near the
Figure 87—Cylinder Head (7.4L Engines) “0” mark on the crankcase front cover. If the valves
V8 ENGINES 6A5B-47
V2881
40. Bolt
41. Ball
42. R ocker Arm
43. Pushrod
44. Hydraulic Lifter
46. C ylinder Head
260. Pushrod Guide
F9325
INTAKE MANIFOLD
INSTALLATION
Tighten
7.4L ENGINES
Figure 91 —Cylinder Head Bolt Tightening
Sequence (7.4L Engines) + 4- Install or Connect (Figures 96 and 97)
are not moving, the engine is in the number one 1. Gaskets (22) to the cylinder heads.
firing position. If the valves move as the mark •Apply a 5 mm (3/16-inch) spot of RTV sealer
comes up to the timing tab, the engine is in the (GM P/N 1052289 or equivalent) on the front
number six firing position and should be turned and rear of the block in four places as shown in
over one more time to reach the number one posi figure 96.
tion. 2. Seals (23) to the block.
3. With the engine in the number one firing position
as determined above, the following valves may be
adjusted:
• Exhaust - 1, 3, 4, 8
• Intake - 1, 2, 5, 7
(Even numbered cylinders are the left bank; odd
numbered cylinders are the right bank, when
viewed from the front of the engine.)
4. Back out the adjusting nut until lash is felt at the
pushrod then turn in the adjusting nut until all lash
is removed. This can be determined by rotating the
pushrod while turning the adjusting nut (figure 93).
When the play has been removed, turn the adjust
ing nut in as follows:
• 5.0L and 5.7L engines: One full turn.
5. Crank the engine one revolution until the pointer
“0” mark and torsional damper mark are again in
alignment. This is the number six firing position.
With the engine in this position the following valves
may be adjusted:
• Exhaust - 2, 5, 6, 7
• Intake - 3, 4, 6, 8 Figure 92—Timing Marks
V8 ENGINES 6A5B-49
4. Bolts (20).
Tighten
1. Gaskets (34).
2. Rocker arm covers (32).
3. Bolts.
Tighten
O • Bolts/studs to specifications:
O — 5.0L and 5.7L engines:
EXHAUST MANIFOLD N O T IC E : R e f e r t o “N o t i c e ” o n p a g e 6 A 5 B - 1 .
INSTALLATION
3. Bolts (12).
Install or Connect (Figures 100 and 101)
^X Tighten
1. Exhaust manifold (1).
2. Spark plug wire heat shields (6).
• Bolts (12) to 40 N-m (30 lbs. ft.).
N O T IC E : R e f e r t o “N o t i c e ” o n p a g e 6 A 5 B - 1 . 4. Bypass hose and clamps (7.4L engine).
A S EA LIN G COM PO U N D
21 INTAKE M AN IFO LD
22 GASKET
23 SEAL
3706S3008
3706S1893
FLYWHEEL INSTALLATION
-n - Install or Connect (Figure 36 and 37)
30 B O LT
32 R O C K ER ARM COVER
3706S3013
3706S3005
ENGINE SET-UP AND TESTING • The pellets must be added to the radiator or the
pressurized coolant reservoir..Iist2— Pellets
• After overhaul, the engine should be tested before
must be crushed prior to installation.
installation in the vehicle. If a suitable test stand is
• Do not place pellets into a non-pressurized
not available, the following procedure can be used
coolant recovery reservoir. On these systems,
after the engine is installed in the vehicle.
the pellets must be added to the radiator.
1. Fill the crankcase with the proper quantity and
• The sealant pellets may leave a film on the
grade of oil.
sides of pressurized and non-pressurized cool
9 Important ant recovery reservoirs. This film is normal.
3. With the ignition “OFF,” or disconnected, crank the
engine several times. Listen for any unusual noises
• If a new camshaft or hydraulic lifters was
or evidence that any parts are binding.
installed, add Engine Oil Supplement (GM P/N
4. Start the engine and listen for unusual noses.
1052367) or equivalent to the engine oil.
5. Run the engine speed at about 1000 rpm until the
Fill the coolant system with the proper coolant.
engine is at operating temperature.
Refer to SECTION 6B1.
6. Listen for improperly adjusted valves or sticking lift
Important ers, and other unusual noises.
7. Check for oil and coolant leaks while the engine is
running.
• Whenever the cooling system is serviced or
8. Use the proper on-vehicle Truck Service Manual or
drained for service procedures, 2 coolant seal
Emission Control Label for adjustment of the igni
ant pellets, (GM P/N 3634621) or equivalent,
tion timing.
must be added to the cooling system.
6A5B-54 V8 ENGINES
SPECIFICATIONS
ENGINE SPECIFICATIONS (5.0U 5.7L )
All Specifications are in INCHES unless otherw ise noted.
GENERAL DATA:
Type V8
Displacement 5.0L (305 CID) 5.7L (350 CID)
RPO (VIN Code) L03 (H) L05 (K)
Bore 3.736 4.00
Stroke 3.480
ie
Compression Ratio 9.1:1
Firing Order 1-8-4-3-6-5-7-2
Oil Pressure (Minimum) 6 PSI @ 1000 RPM; 18 PSI @ 2000 RPM;
24 PSI @ 4000 RPM
CYLINDER BORE:
Diameter 3.7350-3.7385 3.9995-4.0025
Out Of Production 0.001 (Maximum)
Round Service 0.002 (Maximum)
Thrust Side 0.0005 (Maximum)
Production
Taper Relief Side 0.001 (Maximum)
Service 0.001 (Maximum)
PISTON:
Production 0.0007-0.0021
Service Limit 0.0027 (Maximum)
PISTON RING:
C Top
0 Production 0.0012-0.0032
Groove 2nd
M
P Clearance
R Service Limit Hi Limit Production ± 0.001
E Top 0.010-0.020
s Production
s 2nd 0.018-0.026
I
0 Service Limit Hi Limit Production ± 0.010
N
Groove Production 0.002-0.007
0 Clearance Service Limit
1 Hi Limit Production ± 0.001
I Production 0.010-0.030
Gap
Service Limit Hi Limit Production ± 0.010
PISTON PIN:
Diameter 0.9270-0.09271
Clearance Production 0.0004-0.0008
In Piston Service Lmit 0.001 (Maximum)
Fit In Rod 0.0008-0.0016 Interference
*8.3:1 (Over 8500-lb. GVW)
9.1:1 (Under 8500-lb. GVW) T2368
V 8 ENGINES 6A5B-55
SPECIFICATIONS
ENGINE SPECIFICATIONS (5.0L/5.7L) (Cont.)
AH specifications are in INCHES unless otherwise noted.
DISPLACEMENT: 5.0L (305 Cu. In.) | 5.7L (350 Cu. In.)
CRANKSHAFT:
#1 2.4484-2.4493
Diameter #2, #3, #4 2.4481-2.4490
#5 2.4479-2.4488
Main
Production 0.0002 (Maximum)
Journal Taper
Service Limit 0.001 (Maximum)
Out Of Production 0.0002 (Maximum)
Round Service Limit 0.001 (Maximum)
#1 0.0008-0.0020
Production #2, #3, #4 0.0011-0.0023
Main 0.0017-0.0032
#5
Bearing
#1 0.0010-0.0015
Clearance
Service Limit #2, #3, #4 0.0010-0.0025
#5 0.0025-0.0035
Crankshaft End Play 0.002-0.006
Diameter 2.0988-2.0998
Production 0.0005 (Maximum)
Taper
Crankpin Service Limit 0.001 {Maximum)
Out Of Production 0.0005 (Maximum)
Round Service Limit 0.001 (Maximum)
Rod Bearing Production 0.0013-0.0035
Clearance Service Limit 0.003 (Maximum)
Rod Side Clearance 0.006-0.014
CAMSHAFT:
Lobe Intake 0.2336 0.2565
Lift ±0.002 Exhaust 0.2565 0.2690
Journal Diameter 1.8682-1.8692
VALVE SYSTEM:
Lifter Hydraulic
Rocker Arm Ratio 1.50:1
Intake
Valve Lash One Turn Down From Zero Lash
Exhaust
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) 0.002 (Maximum)
Intake 1/32-1/16
Seat Width
Exhaust 1/16-3/32
Intake 0.0010-0.0027
Production
Stem Exhaust 0.0010-0.0027
Clearance Intake High Limit Production +0.001
Service
Exhaust High Limit Production +0.002
Free Length 2.03
Valve
Pressure Closed 76-84 lbs. @ 1.70”
Spring
lbs. @ in. Open 194-206 lbs. @ 1.25”
(Outer)
Installed Height ±1/32” 1 23/32
Valve Spring Free Length 1.86
Damper Approx. # of Coils 4
T2369
6A5B-56 V8 ENGINES
SPECIFICATIONS
ENGINE SPECIFICATIONS (7.4L)
All Specifications are in INCHES unless otherw ise noted.
GENERAL DATA:
Type V8
Displacement 7.4L (454 CID)
RPO L19
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
Out Of Production 0.001 (Maximum)
Round Service 0.002 (Maximum)
Thrust Side 0.0005 (Maximum)
Production
Taper Relief Side 0.001 (Maximum)
Service 0.001 (Maximum)
PISTON:
Production 0.0018-0.0030
Service Limit 0.0036 (Maximum)
PISTON RING:
C Top 0.0012-0.0029
0 Groove Production
M 2nd 0.0012-0.0029
P Clearance
R Service Limit Hi Limit Production +0.001
E Top 0.010-0.018
s Production
s 2nd 0.016-0.024
1
0 Service Limit Hi Limit Production + 0.010
N
Groove Production 0.0050-0.0065
0 Clearance Service Limit Hi Limit Production + 0.001
i
1 Production 0.010-0.030
Gap
Service Limit Hi Limit Production + 0.010
PISTON PIN:
Diameter 0.98945-0.98965
Clearance Production 0.0002-0.0007
In Piston Service Lmit 0.001 (Maximum)
Fit In Rod 0.0031-0.0021 Interference
‘ Measure on a “Warm Engine.” Pressures will be higher on a cold engine.
T2370
V8 ENGINES 6A5B-57
SPECIFICATIONS
ENGINE SPECIFICATIONS (7.4 L) (CONT.)
All S pecifications are in INCHES unless otherw ise noted.
DISPLACEMENT: 7.4L
CRANKSHAFT:
Diameter #1, #2, #3, #4, #5 2.7482-2.7489
Production 0.0004 (Maximum)
Main Taper
Service Limit 0.001 (Maximum)
Journal
Out Of Production 0.0004 (Maximum)
Round Service Limit 0.001 (Maximum)
#1, #2, #3, #4 0.0017-0.0030
Main Production
#5 0.0025-0.0038
Bearing
#1, #2, #3, #4 0.0010-0.0030
Clearance Service Limit
#5 0.0025-0.0040
Crankshaft End Play 0.005-0.011
Diameter 2.1990-2.1996
Production 0.0005
Taper
Crankpin Service Limit 0.001
Out Of Production 0.0005
Round Service Limit 0.001
Rod Bearing Production 0.0011-0.0029
Clearance Service Limit 0.003 (Maximum)
Rod Side Clearance 0.0013-0.023
CAMSHAFT:
Lobe Intake 0.2487
Lift ± 0.002 Exhaust 0.2537
Journal Diameter 1.9477-1.9497
VALVE SYSTEM:
Lifter Hydraulic
Rocker Arm Ratio 1.70:1
Intake
Valve Lash Net Lash
Exhaust
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) 0.002 (Maximum)
Intake 1/32-1/16
oeai vviuin
Exhaust 1/16-3/32
Intake 0.0010-0.0027
Production
Stem Exhaust 0.0012-0.0029
Clearance Intake High Limit Production +0.001
Service
Exhaust High Limit Production +0.002
Free Length 2.15
Valve Pressure Closed 76-84 lbs. @ 1.838-in.
Spring lbs. @ in. Open 205-225 lbs. @ 1.408-in.
Installed Height ± 1/32" 1.838 in.
T2371
6A5B-58 V8 ENGINES
SPECIFICATIONS (CONT.)
FASTENER TIGHTENING SPECIFICATIONS
(5.0L AND 5.7L ENGINES)
Item N-m Lbs. Ft. Lbs. In
Camshaft Sprocket Bolts...................................................................................... 28 21 —
SPECIAL TOOLS
1. J 39046
8. J 23738-A
2. J 8062
9. J 9290-01
3. J 21882
10. J 3049-A
4. J 35468
5. 11. J 5802-01
J 22102
12.
J 5715
13.
J 6036
6. J 8037
14. J 6880
7. J 5239
15. J 5825-A
16. J 5590
1. TORSIONAL DAMPER REMOVER AND INSTALLER
2. VALVE SPRING COMPRESSOR
3. OIL PUMP PICK-UP TUBE INSTALLER
(5.0 AND 5.7L ENGINES)
4. CRANKSHAFT SEAL INSTALLER (5.0L AND 5.7L ENGINES)
5. CRANKSHAFT SEAL INSTALLER (7.4L ENGINE)
17.
6. PISTON RING COMPRESSOR J 35621
7. GUIDE SET 18.
8. VACUUM PUMP J 38841
9. HYDRAULIC LIFTER REMOVER (SLIDE HAMMER TYPE)
10. HYDRAULIC LIFTER REMOVER (PLIER TYPE)
11. STUD REMOVER (5.0L AND 5.7L ENGINES)
12. REAMER (0.003-INCH OVERSIZE) 19. J 28509-A
13. REAMER (0.013-INCH OVERSIZE)
14. STUD INSTALLER (5.0L AND 5.7L ENGINES)
15. CRANKSHAFT SPROCKET PULLER
(5.0L AND 5.7L ENGINES)
16. CRANKSHAFT SPROCKET INSTALLER
17. CRANKSHAFT REAR OIL SEAL INSTALLER
(5.0L AND 5.7L ENGINES)
18. CRANKSHAFT REAR OIL SEAL INSTALLER (7.4L ENGINE)
19. CRANKSHAFT SPROCKET PULLER (7.4L ENGINE)
F9528
NOTES
.
6.5L DIESEL 6A7-1
SECTION 6A7
6.5L DIESEL
RPO L49, VIN P
RPO L56, VIN S
RPO L65, VIN F
RPO L57, VIN Y
NOTICE: When fasteners are removed, always reinstall them at the sam e location from which they were
removed. If a fastener n eed s to be replaced, u se the correct part num ber fastener for that application. If
the correct part num ber fastener is n o t available, a fastener o f equal size and strength (or stronger) m ay
be used. Fasteners that are not reused, and those requiring thread locking com pound will be called out.
The correct torque value m u st be u sed when installing fasteners that require it. If the above conditions
are not followed, parts or sy ste m damage could result.
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................. 6A7- 3
Engine Lubrication............................................................................................................................................... 6A7- 3
Disassembly............................................................................................................................................................... 6A7- 4
Tools and Shop Equipment................................................................................................................................ 6A7- 4
Accessory Removal.............................................................................................................................................. 6A7- 4
Cleaning...................................................................................................................................................................6A7- 4
Flywheel Removal................................................................................................................................................. 6A7- 4
Draining the Engine................................ ............................................................................................................ 6A7- 4
Oil Pump Drive Removal.....................................................................................................................................6A7- 4
Intake Manifold Removal.....................................................................................................................................6A7- 4
Injection Line Removal........................................................................................................................................6A7- 4
Return Line Removal........................................................................................................................................... 6A7- 5
Injection Nozzle Removal....................................................................................................................................6A7- 5
Glow Plug Removal.............................................................................................................................................. 6A7- 6
Exhaust Manifold Removal................................................................................................................................. 6A7- 6
Dipstick Tube Removal........................................................................................................................................6A7- 6
Oil Filler Neck Removal.......................................................................................................................................6A7- 6
Thermostat Housing Removal........................................................................................................................... 6A7- 6
Coolant Crossover Removal.............................................................................................................................. 6A7- 7
Rocker Arm Cover Removal.............................................................................................................................. 6A7- 7
Rocker Arm and Pushrod Removal................................................................................................................. 6A7- 8
Cylinder Head Removal...................................................................................................................................... 6A7- 8
Hydraulic Lifter Removal.....................................................................................................................................6A7- 9
Coolant Pump Removal.......................................................................................................................................6A7- 9
Torsional Damper Removal................................................................................................................................ 6A7- 9
Injection Pump Removal......................................................................................................................................6A7-10
Front Cover Removal........................................................................................................................................... 6A7-10
Timing Chain and Sprocket Removal.............................................................................................................. 6A7-10
Camshaft Removal............................................................................................................................................... 6A7-10
Oil Pan Removal................................................................................................................................................... 6A7-11
Oil Pump Removal............................................................................................................................................... . 6A7-11
Piston and Connecting Rod Rem oval............................................................................................................. 6A7-11
Rear Crankshaft Seal Removal..........................................................................................................................6A7-12
Crankshaft Removal.............................................................................................................................................6A7-12
6A7-2 6.5L DIESEL
CONTENTS (cont’d)
SUBJECT PAGE
Cleaning, Inspection, and Repair..........................................................................................................................6A7-13
Block..................................................... ................................................................................................................. 6A7-13
Oil Filter Bypass Valve and Block Plug..................................................................................................... 6A7-13
Cylinder Bores...................................................................................................................................................... 6A7-13
Cylinder Bore Reconditioning Guidelines.................................................................................................. 6A7-14
Boring.................................................................................................................................................................. 6A7-14
Rough Honing................................................................................................................................................... 6A7-14
Finish Honing.................................................................................................................................................... 6A7-14
Piston and Connecting Rod Assemblies........................................................................................................6A7-14
Disassembly........................................................................................................................................................6A7-14
Cleaning and Inspection................................................................................................................................. 6A7-14
Piston Measurement.........................................................................................................................................6A7-14
Piston Selection................................................................................................................................................ 6A7-15
Measuring Piston Pin to Piston Pin Bushing Clearance..................................... ............ .....................6A7-15
Assembling the Piston and Connecting R o d ............................................................................................6A7-15
Installing the Piston Rings.............................................................................................................................6A7-16
Intake and Exhaust Manifolds...........................................................................................................................6A7-16
Camshaft................................................................................................................................................................. 6A7-16
Camshaft Bearings............................................................................................................................................... 6A7-17
Timing Chain, Sprockets, and Timing G ears................................................................................................ 6A7-18
Front C over............................................................................................................................................................6A7-18
Coolant Pum p........................................................................................................................................................6A7-18
Oil Pan and Rocker Arm Covers..................................................................................................................... 6A7-18
Oil Pump............................................................................................................................................................. . 6A7-19
Valve Train Components..................................................................................................................................... 6A7-19
Hydraulic Lifters................................................................................................................................................6A7-19
Cylinder Head.........................................................................................................................................................6A7-20
Glow Plugs............................................................................................................................................................. 6A7-21
Thermostat and Coolant Crossover................................................................................................................. 6A7-21
Injection Nozzle Tests..........................................................................................................................................6A7-22
Opening Pressure Test.................................................................................................................................... 6A7-22
Leakage Test.......................................................................................................................................................6A7-22
Chatter Test.........................................................................................................................................................6A7-23
Spray Test...........................................................................................................................................................6A7-23
Injection Lines........................................................................................................................................................6A7-23
Injection Pump.......................................................................................................................................................6A7-23
Injection Pump Repair..................................................................................................................................... 6A7-23
Crankshaft and Bearings.................................................................................................................................... 6A7-23
Cleaning and Inspection................................................................................................................................. 6A7-23
Flywheel.................................................................................................................................................................. 6A7-24
Torsional Dam per................................................................................................................................................. 6A7-24
Assembly.................................................................................................................................................................... 6A7-25
Camshaft Installation...........................................................................................................................................6A7-25
Crankshaft Installation.........................................................................................................................................6A7-25
Available Bearing S izes .................................................................................................................................. 6A7-25
Timing Chain and Sprocket Installation..........................................................................................................6A7-26
Front Cover Installation...................................................................................................................................... 6A7-27
Torsional Damper Installation............................................................................................................................6A7-27
Hydraulic Lifter Installation................................................................................................................................ 6A7-28
Connecting Rod and Piston Installation.........................................................................................................6A7-28
Connecting Rod Bearings............................................................................................................................... 6A7-28
Installation...........................................................................................................................................................6A7-28
Marking TDC on the Front Cover................................................................................................................. 6A7-29
Oil Pump Installation............................................................................................................................................6A7-30
Oil Pan Installation...............................................................................................................................................6A7-30
Cylinder Head Installation.................................................................................................................................. 6A7-31
Pushrod and Rocker Arm Installation.............................................................................................................6A7-32
6.5L DIESEL 6A7-3
CONTENTS (cont’d)
SUBJECT PAGE
Rocker Arm Cover Installation..........................................................................................................................6A7-32
Injection Pump Installation................................................................................................................................. 6A7-32
Coolant Pump Installation.................................................................................................................................. 6A7-33
Coolant Crossover Installation..........................................................................................................................6A7-34
Thermostat Housing Installation................................................................................................................. . 6A7-34
Oil Filler Neck Installation.................................................................................................................................. 6A7-35
Dipstick Tube Installation................................................................................................... ............................... 6A7-35
Exhaust Manifold Installation............................................................................................................................. 6A7-35
Glow Plug Installation..........................................................................................................................................6A7-35
Injection Nozzle Installation............................................................................................................................... 6A7-36
Return Line Installation.......................................................................................................................................6A7-36
Injection Line Installation....................................................................................................................................6A7-36
Intake Manifold Installation................................................................................................................................ 6A7-37
Oil Pump Drive Installation................................................................................................................................ 6A7-38
Engine Accessory Installation........................................................................................................................... 6A7-38
Rear Crankshaft Oil Seal Installation.............................................................................................................. 6A7-38
Flywheel Installation............................................................................................................................................. 6A7-38
Engine Setup and Testing.................................................................................................................................. 6A7-38
Specifications............................................................................................................................................................6A7-39
Fastener Tightening Specifications.................................................................................................................. 6A7-39
Engine Specifications..........................................................................................................................................6A7-40
Service Piston and Cylinder Bore Specifications.........................................................................................6A7-41
Crankshaft Main Bearing Selection and Specifications................................. ............................................ 6A7-42
Case, Camshaft and Camshaft Bearings Specifications............................................................................6A7-42
Crankshaft Pin Journals and Connecting Rod Bearings...........................................................................6A7-42
Connecting Rod to Crankshaft Journal Bearing Clearance.......................................................................6A7-42
Special Tools............................................................................................................................................................. 6A7-43
GENERAL DESCRIPTION
The 6.5L diesel engine is a 90-degree V8 type, with ENGINE LUBRICATION
indirect type combustion chambers. There are four ver
sions of the 6.5L engine. Two of the engines are natu A gear-type oil pump is driven from the drive gear.
rally aspirated (L49, VIN P and L57, VIN Y) and the The drive gear is driven by the camshaft. Oil is drawn
other two are turbocharged (L56, VIN S and L65, VIN into the pump through a pickup screen and pipe.
F). Pressurized oil is routed to the oil cooler located
The crankshaft is supported by five precision insert either inside of the radiator or in front of the radiator. A
main bearings, with crankshaft thrust taken at the num bypass valve is provided to protect the cooler from high
ber three (center) main bearing. oil pressures on cold start up. Oil flows from the cooler
The camshaft is supported by five plain type bearings to a full-flow oil filter.
and is chain driven. Motion from the camshaft is trans Oil flows from the oil filter to the oil galleries, provid
mitted to the overhead valves by roller type hydraulic ing pressurized lubrication to various components,
lifters, pushrods, and shaft-mounted rocker arms. The including the turbocharger.
valve guides are integral to the cylinder head. The hydraulic valve lifters receive oil from the oil gal
The connecting rods are forged steel with precision leries. Oil flows from the hydraulic lifters through hollow
insert type crankpin bearings. The piston pins are held pushrods to the rocker arms. Oil from the heads drains
in place by retaining rings. back to the crankcase through oil drain holes.
For engine identification information, refer to SEC The pistons, piston rings, cylinder walls, and connect
TION OA. ing rod small end bearings are lubricated by oil splash.
6A7-4 6.5L DIESEL
DISASSEMBLY
TOOLS AND SHOP EQUIPMENT |^ \| Tighten
• Refer to “TOOLS AND SHOP EQUIPMENT” in
SECTION 6A. • Oil pan drain plug to 24 N-m (17 lbs. ft.).
2. Block drain plugs.
ACCESSORY REMOVAL
• Refer to “ACCESSORY REMOVAL” in SEC Tighten
TION 6A.
$
• Block drain plugs to 22 N-m (16 lbs. ft.).
CLEANING
NOTICE: Clean the engine only when it is OIL PUMP DRIVE REMOVAL
cold, and never when the engine is running.
Spraying or pouring water or other fluids on Remove or Disconnect (Figure 2)
the engine when it is warm or hot, or when it
is running, can cause serious damage to the 1. Speed sensor wire (L57, VIN Y only).
engine and its com ponents. 2. Hold down clamp and bolt.
3. Oil pump drive. Pull out to remove.
• Refer also to "CLEANING" in SECTION 6A.
4. Gasket.
FLYWHEEL REMOVAL
INTAKE MANIFOLD REMOVAL
Remove or Disconnect (Figure 1)
Remove or Disconnect (Figures 3 and 4)
1. Bolts.
2. Flywheel. Tool Required:
J 29664 Manifold Cover Set
DRAINING THE ENGINE 1. Intake manifold bolts and fuel line clips.
*"► Remove or Disconnect 2. Intake manifold.
3. Gaskets.
1. Oil pan drain plug. • Install J 29664-1 to the intake ports.
• Allow the oil pan to drain.
2. Oil filter.
3. Block drain plugs.
INJECTION LINE REMOVAL
• Allow the coolant to drain.
gjjjl Clean
*4 - Install or Connect
• All injection line fittings at the nozzles and injection
1. Oil pan drain plug. pump.
Tool Required:
J 29873 Nozzle Socket
1. Clamps.
2. Fuel return hoses at injector nozzles. Figure 6—Return Lines
6A7-6 6.5L DIESEL
THERMOSTAT
HOUSING/THERMOSTAT
REMOVAL
Remove or Disconnect (Figures 12 and 13)
Important
Important
Important
Tool Required:
J 39046 Torsional Damper Remover
J 23523-2 Screw
CAMSHAFT REMOVAL
Remove or Disconnect (Figure 26)
1. Bolts.
2. Oil pan.
3. Oil pan rear seal.
1. Bolt.
2. Oil pump and extension shaft.
CRANKSHAFT REMOVAL
A. Cloth
F9385
Remove or Disconnect (Figure 32)
Figure 30— Removing the Cylinder Ridge
• Marking them from the front to the rear, with the • Check the main bearing caps for location markings.
engine in an upright position and viewed from Mark the caps if necessary. The caps must be
the front. - The right bank is numbered 1-3-5-7. returned to their original locations during engine
- The left bank is numbered 2-4-6-8. reassembly.
3. Mark the connecting rods and caps if they are not
marked. 1. Main bearing cap bolts.
• Marking them from the front to the rear with the 2. Main bearing caps.
engine in an upside down position. - The right 3. Crankshaft.
bank is numbered 2-4-6-8. - The left bank is
• Lift the crankshaft straight up, taking care to
numbered 1-3-5-7.
avoid damage to the crankshaft journals and
• Be sure to mark both the rod and the cap with
the correct cylinder number. The connecting rod thrust flange surfaces.
and cap must be kept together as mating parts. 4. Main bearing inserts. If the bearing inserts are to
4. Connecting rod nuts and cap. be reused, place them in a rack so they can be
5. Connecting rod and piston. installed in their original location.
A. Attach two short pieces of 10-mm (3/8-inch)
hose to the connecting rod bolts (figure 29).
This will protect the crankshaft journal during
removal.
B. Push the connecting rod and piston out of the
bore.
C. After removal, assemble the connecting rod,
cap and bearings.
• Bearing inserts must be kept in the rods and
caps that they came out of if they are to be
reused.
CYLINDER BORES
I9 Inspect
Figure 33—Oil Filter and Oil Cooler Bypass Valves • Cylinder bores for scoring and other damage.
6A7-14 6.5L DIESEL
ROUGH HONING
Refer to “HONING” in SECTION 6A.
• When taking the final pass with the rough hone,
leave approximately 0.005 mm (0.0002 inches) on
the diameter for finish honing.
FINISH HONING
Refer to “HONING” in SECTION 6A.
• The following is the surface roughness specifica
tion for cylinder bores.
RA (Minimum) = 0.40 Micro-meter (16 micro-inch)
RA (Maximum) = 0.90 Micro-meter (32 Micro-inch) Figure 34— Measuring Piston Skirt Diameter
6.5L DIESEL 6A7-15
PISTON SELECTION
To determine the piston to cylinder bore clearance
perform
the following measurements:
Measure
Clean
Tool Required:
J 39507 Piston Retaining Ring Installer
1. Piston to the connecting rod.
6A7-16 6.5L DIESEL
Measure
* Assemble
Measure
Tool Required:
J 33049 Universal Camshaft Bearing Remover
• 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 POSI
TION. The cam bearing bores vary in size. The
cam bearings are numbered 1 through 5, with
the numbers located on the back of the bearing.
1. Rear camshaft bearing. Drive the bearing into
place using J 33049 from the front of the block.
Installation is the reverse of removal.
Important
Camshaft journals. Use a micrometer. The proper 2. Front camshaft bearing. Drive the bearing into
place using J 33049 from the back of the block.
journal dimensions are as follows:
• #5 (rear) journal: 50.975 to 51.025 mm (2.0069 9 Important
to 2.0089 inches).
•A ll others: 54.975 to 55.025 mm (2.1644 to
• The notch in the bearing must face the front of
2.1663 inches).
the block.
CAMSHAFT BEARINGS • There are two oil holes in the front cam bearing.
Using the seam in the 11 o’clock position as a
reference point, one oil hole will be in the 1
I? Inspect
o’clock position, and the other hole will be in
Camshaft bearings for scratches, pits, or loose fit in the 4:30 position.
their bores. Replace the camshaft bearings if nec • The front bearing must be installed with the
essary. seam in the 11 o,clock position, with the notch
facing to the front of the block, and the top oil
Disassemble (Figures 41 and 42) hole in the bearing at the 1 o’clock position, in
* line with the oil hole in the block that is in the
Tools Required: same location.
J 33049 Universal Camshaft Bearing Remover 3. Inner camshaft bearings using J 33049. Installation
and Installer Kit is the reverse of removal.
1. Rear camshaft plug.
2. All camshaft bearings using J 33049 (figure 41).
A. Insert the tool with the correct collet into the
camshaft bearing you want to replace.
B. Turn the tool until the collet has tightened in the
bearing.
C. Push the centering cone against the block and
into the first bearing bore to center the tool.
D. Drive the bearing from the block using the
appropriate hammer.
E. Hold the bearing while turning the tool to
release the collet and remove the bearing.
F. Repeat this procedure to remove the remaining
camshaft bearings. Note that the rear bearing
must be removed from the front of the block
and the front bearing should be removed from
the rear. This allows the tool to remain cen
tered.
jjjj| Clean
• Camshaft bearing bores in the block. Figure 41—Replacing the Camshaft Bearinqs
6A7-18 6.5L DIESEL
Important Important
1? Inspect
L* Inspect
Hydraulic lifter rollers for fatigue or pitting, replace
Oil pump operation. Turn the drive shaft by hand
lifter as an assembly.
and check for smooth rotation.
Important
VALVE TRAIN COMPONENTS
Some engines will have both standard and a
Important 0.010-inch oversize hydraulic lifters. The oversize
lifter will have a “10” etched on the side. The block
Store all reusable components in an exact order so will be stamped “O.S.” on the cast pad adjacent to
they may be reassembled in the same position the lifter bore and on the top rail of the cylinder
from which they were removed. case above the lifter bore.
6A7-20 6.5L DIESEL
CYLINDER HEAD
The 6.5L light duty naturally aspirated engine uses a
39-mm (1.53-inch) non-stellite faced exhaust valve.
Both turbocharged and heavy duty naturally aspirated
engines use a 39-mm (1.53-inch) stellite faced exhaust
valve. All engines use the same size intake valve that is
46 mm (1.81 inch). Intake and exhaust valves with
oversize stems are available in 0.09 mm (0.03 inch)
and 0.39 mm (0.153 inch) oversize.
Tool Required:
J 8062 Valve Spring Compressor
1. Valve keepers.
A. Compress the valve springs with J 8062 (figure
42).
B. Remove the valve keepers.
C. Remove J 8062.
Cleaning and Inspection of Components
2. Caps, rotators, shields, valve springs with dampers
and shims. KW Clean
3. Valve seals.
4. Valves. Place them in a rack so they can be Components as outlined in SECTION 6A.
returned to their original position at assembly.
5. Prechambers (if required) (figure 43). L* Inspect
• Drive out with a small nylon or brass drift insert 1. Components outlined in SECTION 6A. Replace all
ed through the injection nozzle hole. valve springs at overhaul.
• The light and heavy duty naturally aspirated 2. Prechambers for cracks. Replace any prechambers
engines along with the light duty turbocharged with facial cracks longer than 5 mm (3/16 inch).
engine have prechambers that are constructed Service prechambers are available in standard and
0.254-mm oversize.
of high temperature super alloy material.
The heavy duty turbocharged engine uses the Measure
same high temperature super alloy material but
its throat size is larger and its internal dimen 1. Valve stem clearance. Refer to SECTION 6A.
sions are different than the light and heavy duty 2. Cylinder head warpage. Refer to SECTION 6A. If
naturally aspirated engines and light duty turbo the head is w a rp e d m ore than 0 .1 5 -m m
charged engine. (0.006-inch) longitudinally or 0.08-mm (0.003-inch)
transversely, replace the cylinder head.
NOTICE: Resurfacing the cylinder head is not
reco m m en d ed due to the extrem ely clo se
valve to piston clearances.
3. Cylinder head thickness (rocker arm cover gasket
rail to head gasket surface) must be at least 97.87
mm (3.853 inch).
4. Valve protrusion. This is the distance the valve is
extended past or recessed into the firedeck. If the
valve is past specification (recessed too far) the
pushrod can bottom out in the lifter and hold the
valve open. Spring seat tension will be lost, as well
as compression. To d e c k the valve protrusion use
J 4209-25 sled gage, with plunger resting on the
surface of the firedeck. Set gage to 0 then move
the plunger over each valve and note the reading
on the gage. This measurement will be the amount
of valve protrusion, Maximum protrusion is - 1.143
mm (0.045 inches) for intake and - 0.889 mm
(0.035 inches) for exhaust. The denotes that the
valve is recessed into the head.
6.5L DIESEL 6A7-21
NOTICE: Valve se a ts on 6.5L en g in es are Valve spring installed height of each valve spring,
induction-hardened. E x c e ssiv e rem oval o f as follows:
s to c k m ay resu lt in dam age to the valve 1. Use a narrow, thin scale. A cutaway scale may
seats. be helpful (figure 44).
2. Measure from the valve shim or spring seat to
* Assemble (Figures 42 and 43) the top of the shield (figure 45).
3. If this measurement exceeds the figure given in
Tool Required: “Specifications,” install valve spring seat shims
J 8062 Valve Spring Compressor of sufficient thickness (between the spring and
1. Prechambers (if removed) (figure 43). cylinder head) to give the desired measure
A. Align the locating notches. The prechamber will ment. Never shim the spring so as to give an
fit correctly in only one position. installed height under the specified figure.
B. Tap into place. Use a 32-mm (1 1/4-inch) sock
et. GLOW PLUGS
Measure L* Inspect
Refer to “Valve protrusion” for how to mea • Glow plugs for stripped threads and damage.
sure prechamber installed depth. Replace the glow plugs if the tips are cracked,
• Prechamber installed depth. The prechamber bulged, or broken.
should be flush to a maximum of 0.05 mm
(0.002 inch) protrusion. ^ j| Measure
• Make the measurement at two or more
points on the precham ber w here the • Glow plug resistance. Connect an ohmmeter
prechamber seats on the head gasket shield between the electrical connector blade and the
and sealing ring. glow plug body. Replace any glow plug with a
• Measure the difference between the flat of resistance greater than 2 ohms.
the prechamber and the flat surface of the
cylinder head. THERMOSTAT AND COOLANT
•T h e prechamber must not protrude out of CROSSOVER
the cylinder head more than 0.05 mm (0.002
There are two different types of thermostats used on
inch).
the 6.5L diesel engine. The C/K models use a “blocking
• The prechamber must not be recessed into
bypass” type thermostat. The poppet at the bottom of
the cylinder head.
this thermostat closes off the coolant bypass hose when
2. Valves. the engine is at operating temperature and the thermo
A. Lubricate the valve stems with engine oil. stat is fully open. This causes all coolant to flow
B. Insert the valves into the proper ports. through the radiator. Due to space restrictions, the P
3. Shims. truck and G-van models use a conventional “balance
4. Valve seals (exhaust valves only). Install the valve type” thermostat.
seals over the valve stems and seat them against
the heads.
5. New valve springs with dampers.
6. Shields.
7. Caps (intake valves only).
8. Rotators (exhaust valves only).
9. O-ring seals and valve keepers.
A. Compress the valve spring, using J 8062 (figure
42). Compress the spring enough so the lower
valve stem groove can be clearly seen.
B. Push a new seal onto the valve stem. The seal
is to be installed on the stem’s lower groove.
Make sure the seal is flat and not twisted.
C. Apply a small amoi#t of grease to the area of
the upper valve stem groove. Assemble the two
valve keepers using the grease to hold the
keepers in place. Make sure the keepers seat
properly in the groove.
D. Release the compressor tool. Make sure the
valve keepers stay in place.
E. Repeat the preceding steps on the remaining
valves. Figure 44— Cutaway Scale
6A7-22 6.5L DIESEL
CAUTION: When testing nozzles, do not place B. Main bearing inserts. Wipe free of oil with a soft
your hands or arms near the top of the noz cloth.
zle. The high pressure atomized fuel spray
from a nozzle has sufficient penetrating pow 1? Inspect
er to puncture flesh and destroy tissue and
may result in blood poisoning. The nozzle tip A. Crankshaft for cracks. Use the magnaflux method,
should always be enclosed in a receptacle if available.
preferably transparent, to contain the spray. B. Crankpins, main bearing journals, and thrust sur
faces for scoring, nicks, or damage caused by lack
2. Depress the lever of the test stand slowly and note of lubrication.
whether chatter noise can be heard. C. Main bearing inserts for scoring or other damage.
3. If no chatter is heard, move the lever faster until it
In general, the lower inserts (except the #1 bearing)
chatters. At fast lever movement, the nozzle may
show greater wear and the most distress from fatigue.
make a“hissing” or “squealing” sound rather than
the normal chatter. This is acceptable. If, upon inspection, the lower insert is suitable for use, it
4. These sounds indicate that the nozzle needle can be assumed that the upper insert is also satisfacto
moves freely and that the nozzle seat, guide, and ry. If the lower insert shows evidence of wear or dam
pintle are OK. age, both the upper and lower inserts must be replaced.
5. Replace nozzles that do not chatter.
% Measure (Figures 46 and 47)
SPRAY PATTERN
This nozzle features a longer nozzle overlap, greater A. Main bearing and connecting rod journal diameters
pintle to body clearance, and an internal wave washer (figure 46). Compare with “Specifications.” replace
between the nozzle nut and the nozzle. These features the crankshaft if necessary.
make objective spray pattern testing difficult. B. Main bearing and connecting rod journals for taper
A pop tester will not deliver fuel fast enough for prop and out-of-round (figure 46). If the journals are
er spray pattern analysis. Based on this, this type of tapered or out-of-round more than 0.025 mm
nozzle should not be rejected for spray pattern. (0.001-inch), replace the crankshaft.
Replace any faulty nozzles. Do not attempt repairs.
C. Crankshaft runout (figure 47).
FLYWHEEL
Clean
i? Inspect
TORSIONAL DAMPER
I? Inspect
B4523
• Bolts to specifications, in the following 1. Crankshaft sprocket with mark facing the front.
sequence: 2. Camshaft sprocket with timing chain with mark on
a. Inner bolts: 150 N-m (110 lbs. ft.). sprocket facing the front.
b. Outer bolts: 135 N-m (100 lbs. ft.).
c. R e tig h te n all bolts in th e sam e Important
sequence.
6. Numbers 1, 2, and 4 main bearing caps and bolts.
• Align the timing marks (figure 51).
a Tighten 3. Camshaft gear, washer and bolts.
5. Move the chain inward (parallel to the front face 1. Torsional damper. Tap into place with a mallet.
of the block) the maximum amount with finger Make sure the key is in place. Make sure the
pressure on the outside of the chain. damper is all the way on the crankshaft.
6. The total indicator travel can be noted. With 2. Bolt and washer.
used parts, the deflection must not exceed 20.3
mm (0.80 inch). If the deflection exceeds this Tighten
limit, the sprockets and timing chain must be £
inspected for wear and replaced as necessary.
With new parts, the deflection must not exceed • Bolt to 270 N-m (200 lbs. ft.).
12.7 mm (0.50 inch). • Align timing bracket with mark on torsional
• Do not turn the crankshaft or change the damper at 0° TDC.(Figure 51)
alignment of the timing gears until after the
3. Timing bracket and bolts
torsional damper is installed.
NOTICE: If the timing chain, timing gears, $ Tighten
fro n t co ver, c ra n k sh a ft p o s itio n s e n s o r,
crankshaft or other com ponent(s) affecting Bolts to 6-12 N-m (53-106 lbs. in.)
timing are replaced, it will be necessary to
reprogram TDC O ffset into the PCM. Refer to
the appropriate Driveability, Em issions and
Electrical Diagnosis Manual. (L49 VIN P, L56
VIN S, L65 VIN F only)
I? Inspect
Tighten
a Tighten
Important
TORSIONAL DAMPER
INSTALLATION
Install or Connect
Important
1. Hydraulic lifters to the engine.
A. Prime new hydraulic lifters before installation by • When using selective fit rod bearings, always use
working the lifter plunger while submerged in the standard bearing in the connecting rod, use the
clean kerosene or diesel fuel. undersize bearing in the rod cap. Also note that the
B. Coat the lifter roller and bearings with lubricant color coding for selective fit rod bearings are differ
(GM P/N 1052365) or equivalent. ent from the color coding for main bearings.
C. Lifters MUST be installed in their original loca • Connecting rod bearings are available in 0.026 mm
tions. (0.001-inch) undersizes for select fitting.
2. Guide plates.
3. Clamps. • Turbocharged and naturally aspirated light duty
emissions engines may have both standard and
0.08-mm (0.003-inch) OVERSIZE connecting
rod bearings. The oversize connecting rods are
stamped “O.S.” on the cap’s lower end.
INSTALLATION
Tool Required:
J 8037 Ring Compressor
A. Make sure the cylinder walls are clean. Lubricate
the cylinder wall lightly with engine oil.
B. Make sure the piston is installed in the matching
cylinder. Install new pistons in the cylinders for
which they were fitted. Install used pistons in the
cylinder from which they were removed.
1. Connecting rod bearings.
A. Be certain that the bearings are the proper size.
B. Install the bearings in the connecting rod and
connecting rod cap.
6 .5 L DIESEL 6A7-29
Important
Figure 57—Measuring Connecting Rod Side Figure 59—Injection Pump Timing Gears
Clearance
5. Install one 10-mm nut to the upper housing stud to
hold the tool flange.
• The nut should be finger tight.
6. Tighten the large bolt (19-mm head) clockwise
(looking at the front of the engine) to 48 N-m (35
lbs. ft.).
7. Tighten the 10-mm nut.
8. Check that the crankshaft has not rotated and that
the tools did not bind.
9. Strike the scriber with a mallet to mark TDC on the
front cover.
10. Remove J 33042.
& Tighten
m Tighten
ROCKER ARM COVER Align the timing marks. Be certain the mark on
INSTALLATION the injection pump gear is aligned with the mark
on the camshaft gear. For the proper timing of
| Clean the injection pump, cam gear timing mark must
be in the 12 o’clock position. Rotate the crank
Sealing surfaces on the cylinder head and rocker shaft to bring the cam gear timing mark up to
arm cover with carburetor cleaner or equivalent. the 12 o’clock position.
6.5L DIESEL 6A7-33
Tighten
Adjust
$ Tighten
Figure 70—Applying Sealer to the Coolant Pump
Nuts to 40 N m (30 lbs. ft.) (figure 67). Plate
6A7-34 6.5L DIESEL
Figure 71—Coolant Pump Plate to Front Cover Figure 73—Coolant Crossover (G and P Models)
Tighten
COOLANT CROSSOVER
• Bolts to 28 N-m (20 lbs. ft.). INSTALLATION
•A p p ly a bead of anaerobic sealer (GM P/N
1052357) or equivalent to the coolant pump plate -►4- Install or Connect (Figures 72 and 73)
as shown in figure 70.
3. Coolant pump plate to the engine. The sealer must
1. Gaskets.
be wet to the touch when installing the plate.
2. Coolant crossover.
•Apply sealant (GM P/N 1052080) or equivalent to 3. Bolts and studs.
the threads of bolts and studs as shown in figure
70. Tighten
4. Bolts and studs.
$
• Bolts and studs to 42 N-m (31 lbs. ft.).
Tighten
4. Hose and clamps.
A. Coolant pump to front cover bolts to 42 N-m (32 5. Engine coolant temp. sensor.(L49,L56 and L65
lbs. ft.). only)
B. Coolant pump plate to front cover bolts to 28 6. Fuel return lines.
N-m (20 lbs. ft.). 7. Fuel return pipe in valley prior to installing the
intake manifold.
THERMOSTAT
HOUSING/THERMOSTAT
INSTALLATION
1. Thermostat.
2. Gasket
3. Thermostat housing.
4. Bolts/Studs
Tighten
Tighten
Glow plugs.
Tighten
1. Seal.
2. Oil filler neck.
3. Nuts holding bracket to front cover.
4. Nut holding bracket to thermostat housing.
DIPSTICK TUBE
INSTALLATION
Install or Connect
INJECTION LINE
INSTALLATION
+ 4- Install or Connect (Figure 82)
INJECTION NOZZLE
INSTALLATION
Install or Connect
Tool Required:
J 29873 Nozzle Socket
Tighten
a Tighten
INTAKE MANIFOLD
INSTALLATION
Remove or Disconnect
Tool Required:
J 29664 Manifold Cover Set
Figure 85—Intake Manifold Right Side
£ Tighten
Tighten Important
$
• Bolt to 42 N-m (31 lbs. ft.). • Coat the crankshaft surface with engine oil, and
lightly coat the lip of the new oil seal with engine
4. Speed sensor wire.(Figure 86, L57 only)
oil or grease before installing the new oil seal. Do
not scratch or nick the sealing edge of the oil seal.
1. The oil seal, with the spring cavity towards the
engine, onto the crankshaft.
2. Using J 39084 installation tool, drive the seal in
until the tool bottoms against the block and rear
main bearing cap.
FLYWHEEL INSTALLATION
+4- Install or Connect (Figure 89)
1. Flywheel.
2. Bolts.
Tighten
SPECIFICATIONS
FASTENER TIG HTENING SPECIFICATIONS
Item N-m Lbs. Ft. Lbs. In.
Bell Housing Bolts.................................................................................................. 40 30 —
Block Drain Plugs................................................................................................... 22 16 —
Camshaft Gear Bolt............................................................................................... 171 126 —
Camshaft Thrust Plate........................................................................................... 23 17 —
Connecting Rod Cap Nuts.................................................................................... 65 48 —
Coolant Crossover/Thermostat Housing Bolts................................................... 42 31 —
Crankshaft Pulley Bolts......................................................................................... 40 30 —
Cylinder Head Bolts— Refer to Procedure......................................................... — — —
Exhaust Manifold Bolts......................................................................................... 35 26 —
Flywheel Bolts......................................................................................................... 90 66 —
Front Cover to Block Bolts................................................................................... 45 33 —
Glow Plugs.............................................................................................................. 18 13 —
Hydraulic Lifter Guide Plate Clamp Bolts.......................................................... 26 19 —
Intake Manifold Bolts.............................................................................................. 42 31 —
Injection Lines........................................................................................................ 33 24 —
Injection Nozzles.................................................................................................... 80 59 —
Injection Pump Gear Bolts.................................................................................... 23 17 —
Injection Pump Nuts............................................................................................... 42 31 —
Oil Filter Adapter Bolt............................................................................................ 65 47 —
Main Bearing Cap Bolts— Inner........................................................................... 150 111 —
Outer.......................................................................... 135 100 —
Oil Pan Bolts (all except rear two bolts)............................................................ 10 — 89
(rear two bolts)............................................................................. 23 17 —
Oil Pump Bolt.......................................................................................................... 90 66 —
Oil Pan Drain Plug..................... ........................................................................... 27 20 —
Oil Pump Cover Screws....................................................................................... 16 12 —
Oil Pump Drive Clamp Bolt.................................................................................. 42 31 —
Rocker Arm Cover Bolts....................................................................................... 22 16 —
Rocker Arm Shaft Bolts........................................................................................ 55 41 —
Torsional Damper Bolt............................................................................................ 270 200 —
Turbocharger to Exhaust Manifold Nuts............................................................. 50 37 —
T2841
6A7-40 6.5L DIESEL
ENGINE SPECIFICATIONS
All Specifications are In m illim eters (mm) unless otherw ise noted.
GENERAL DATA:
Displacement 6.5L
RPO L49, L56, L57, and L65
Type 90-degree V8 Diesel
Bore 103
Stroke 97
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 “Service Piston and Bore Specifications”
Out Of Round 0.02 (Maximum)
Taper (Thrust Side) 0.02 (Maximum)
PISTON DIAMETER: Refer to “Service Piston and Bore Specifications”
Piston to Bores 1 through 6 .094-0.120
Bore Clear Bohn Pistons
Bores 7 and 8 0.107-0.133
ance
PISTON RING:
Top Keystone Type Ring
Groove Clearance
2nd 0.039-0.079
Compression
Top 0.26-0.51
Gap2
2nd 0.75-1.00
Groove Clearance 0.040-0.090
Oil
Gap 0.25-0.51
PISTON PIN:
Diameter 30.9961-31.0039
Clearance (Piston Pin to Piston Bore) 0.0101-0.0153
Fit in Rod (Piston Pin to Rod Pin Bushing) 0.0081-0.0309
CRANKSHAFT:
#1, #2, #3, #4 Refer to “Crankshaft Main Bearing Selection” Specifi
Diameter
Main #5 cations
Journal Taper 0.005 (Maximum)
Out of Round 0.005 (Maximum)
#1, #2, #3, #4 0.045-0.083
Main Bearing Clearance
#5 0.055-0.093
Crankshaft End Play 0.10-0.25
Diameter 60.913-60.939
Crankpin Taper 0.005 (Maximum)
Out-of-Round 0.005 (Maximum)
Rod Bearing Clearance (Select Fit) 0.045-0.100
Rod Side Clearance 0.17-0.63
1NOTE: Add 0.013mm to cylinder bore diameters to determine proper bore size for cylinders #7 and #8.
2NOTE: Ring end gap specifications are for new bores, worn bores will generate larger ring end gaps.
T2842
6.5L DIESEL 6A7-41
■^Iq
OOIOO
^ |o
OOIOO
ooioo
t-Jo
.18
Press Fig (Bearing to Case) .08
Note: In order to cover all possible service conditions (i.e., old cam with large journal diameter matched with new
block with small bore diameter), the camshaft and camshaft bearing service specifications are different than pro
duction specifications.
T3034
SPECIAL TOOIS
7. e m ftff J 39046
1. J 8037
2 . J 33049 8. 29664
3.
9. J 8062
4.
10. J 24270
5.
11. J 39083
6.
J 39507
12 .
a 3 Z J
1. RING COMPRESSOR
2. UNIVERSAL CAMSHAFT BEARING
REMOVER AND INSTALLER SET
3. NOZZLE SOCKET 13. J 33042
4. SEAL INSTALLER
5. NOZZLE TESTER
6. REAR CRANKSHAFT SEAL INSTALLER 10. RIDGE REAMER
7. TORSIONAL DAMPER REMOVER 11. OIL PRESSURE SENDING UNIT SOCKET
8. MANIFOLD COVER SET 12. PISTON PIN RETAINER RING INSTALLER
9. VALVE SPRING COMPRESSOR 13. STATIC TIMING GAUGE (L57 ONLY)
I........... —
NOTES
T€0i I
ow n
T38 p : .-mm rkA b3vom* •
T3X0QB 3JXI0
R 5 ^ ri n | j A . IA jf8 > m *4 C 8 A 3 !. ?
' ■■ j ,
m ■ja t< ’ Vis ,,mm n m \ A i : w .tin iv o o qjq ^M h j z
tfQ VSJ) 3DUA0 0WJMT 0?TAT8 gf
MODEL 220 TBI U N IT 6C1-1
SECTION 6C1
---------------------------- ■
NOTES
SD ENGINE ELECTRICAL 6D-1
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
SUBJECT PAGE
SD Starter M otors..................................................................................................................................................... 6D2A-1
28-MT Starter Motors................................................................................................................................................6D2B-1
CS-144 Generators.................................................................................................................................................... 6D3A-1
Distributors.................................................................................................................................................................. 6D4A-1
High Voltage Switch..................................................................................................................................................6D4B-1
NOTES
. -V'S... *
t. ■ if- %‘ ■■■
* >,'139
•■V-C-
........
'
V-Xi;A1 W.
.
SD STARTER MOTORS 6D2A-1
SECTION 6D2A
SD STARTER MOTORS
NOTICE: When fasteners are removed, always reinstall them at the sam e location from which they were
removed. If a fastener n eed s to be replaced, u se 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. Fasteners that are not reused, and those requiring thread locking com pound will be called out.
The correct torque value m u st be u sed when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................6D2A-2
Delco Remy SD Starter Motors......................................................................................................................... 6D2A-2
Identification.......................................................................................................................................................6D2A-2
Diagnosis.....................................................................................................................................................................6D2A-2
Starter Motor Tests............................................................................................................................................... 6D2A-2
No-Load Test.......................................................................................................................................................... 6D2A-2
Disassembly of the SD-210 and SD-260 Starter M otors................................................................................ 6D2A-3
Solenoid...................................................................................................................................................................6D2A-3
Frame and Field Assembly................................................................................................................................ 6D2A-3
Drive End Frame Assembly............................................................................................................................... 6D2A-3
Inspection....................................................................................................................................................................6D2A-4
Cleaning, Inspection, and Electrical Tests......................................................................................................6D2A-4
Assembly of the SD-210 and SD-260 Starter M otors......................................................................................6D2A-6
Drive End.................................................................................................................................................................6D2A-6
Frame and Field Assembly................................................................................................................................ 6D2A-6
Pinion Clearance Check......................................................................................................................................6D2A-7
Specifications............................................................................................................................................................ 6D2A-8
Starter....................................................................................................................................................................... 6D2A-8
Solenoid Switches................................................................................................................................................ 6D2A-8
Fastener Tightening Specifications...................................................................................................................6D2A-8
Lubrication.............................................................................................................................................................. 6D2A-8
6D2A-2 SD STARTER MOTORS
GENERAL DESCRIPTION
DELCO REMY SD
STARTER MOTORS
The straight-drive type starter motors covered in this
section have enclosed shift levers (figure 1).
The starter motor has the drive end housing extended
to enclose the shift lever and solenoid plunger. The
solenoid flange mounts to the extension of the drive
end housing with sealing compound between the flange
and the field frame.
The starter motor bearings are lubricated during
motor assembly and do not require service except dur
ing motor repair.
IDENTIFICATION
The part number can be found either stamped on the
outside of the C.E. frame or on an identification tag
attached by a through bolt.
Figure 1—SD-Series Starter Motor (Typical)
DIAGNOSIS
STARTER MOTOR TESTS 3. Failure to operate with high current draw indicates:
• A direct ground in the terminal or fields.
Before disassembling the starter motor for repair, the
• Seized bearings. This should have been noted
following test should be made.
by turning the armature by hand.
NOTICE: N ever operate the starter m otor 4. Failure to operate with no current draw indicates:
m ore than 30 s e c o n d s at a tim e w ithout • Open field circuit. This can be checked after
pausing to allow it to cool for least two min disassembly by inspecting internal connections
u te s. O verheating, c a u s e d b y to o m u ch and tracing the circuit with a test lamp.
cranking, will dam age the starter motor. • Open armature coils. Inspect the commutator
for badly burned bars after disassembly.
• Broken brush springs, worn brushes. High
NO-LOAD TEST insulation between the commutator bars or oth
Connect a voltmeter from the motor terminal to the er causes which would prevent good contact
motor frame and an RPM indicator to measure arma between the brushes and commutator.
ture speed (figure 2). Connect the motor and an amme
ter in series with a fully charged battery of the specified
voltage, and a switch in the open position to the switch
terminal. Close the switch and compare the RPM, cur
rent, and voltage readings with the specifications at the
end of this section. It is not necessary to obtain the
exact voltage that if the voltage is slightly higher the
rpm will be slightly higher, with the current remaining
basically unchanged. However, if the exact voltage is
desired, a carbon pile connected across the battery can
be used to reduce the voltage to the specified value.
Compare the test results as follows:
1. Rated current draw and no-load speed indicates
normal condition of the starter motor.
2. Low free speed and high current draw indicates:
• Too much friction. Tight, dirty or worn bear
ings, bent armature shaft or loose pole shoes
allowing the armature to drag.
• Shorted armature. This can be further checked
on a growler after disassembly.
• Grounded armature or fields. Check further
after disassembly.
SD STARTER MOTORS 6D2A-3
5. Low no-load speed and low current draw indicates 6. High free speed and high current draw indicates
a higher internal resistance due to poor connec shorted fields. If shorted fields are suspected,
tions, defective leads, dirty commutator and causes replace the field coil assembly and check for
listed under step 4. improved performance.
INSPECTION
CLEANING, INSPECTION, AND • Shorts between the commutator bars are some
times produced by brush dust or copper dust.
ELECTRICAL TESTS 5. Armature for opens.
IjjJP Clean • Look for loose connections where the conduc
tors join the commutator bars. Poor connections
cause arcing and burning of the commutator.
NOTICE: Do not clean the starter m otor parts
in a degreasing tank. Immersing parts in a 6. Armature for grounds using a self powered test
cleaning solution will d isso lve perm anent lamp (figure 6).
lubrication and m ay damage electrical insula • If the test lamp lights when one test probe is
tion, causing shortened m otor life. placed on the commutator and the other test
probe is placed on the armature core or shaft,
• All parts by wiping with a clean cloth. the armature is grounded.
7. Brushes for wear. If the brushes are worn to half
L* Inspect (Figures 5 through 8)
the size of a new brush, replace the brushes. On
the SD-260, the brushes and brush holders are an
1. Bushing or armature bearing fit in the end frame,
integral part of the frame and field assembly, so the
lever housing, and drive end frame housing. If the
assembly must be replaced.
bushings or bearings are damaged or worn,
8. Brush holders for dirt or damage.
replace them.
• Lubricate the bushings before assembling the • Make sure that the brushes are not binding in
starter motor. Avoid excessive lubrication. Do the holders.
not lubricate roller bearings. They are perma 9. Brush springs for distortion or discoloring. If the
nently lubricated at time of manufacture. springs are weak, bent, or discolored, replace
2. Armature shaft for runout or scoring. Replace the them. On the SD-260, replace the frame and field
armature assembly if the condition of the armature assembly.
shaft is doubtful. 10. Field coils.
3. Commutator for discolored or uneven conductors.
• Look for burned or damaged insulation, dam
— Do not turn the commutator.
aged connections or loose poles. If the condi
— Do not undercut the insulation.
tion of the coils is doubtful, replace the field and
— Clean the commutator with No. 240 grit emery
frame assembly.
cloth. Blow away any copper dust present. If
the commutator cannot be cleaned, replace the 11. Field coils for grounds.
armature. • Connect a self-powered test lamp between the
4. Armature for short circuits (figure 5). field frame and the field connector. Make sure
• Rotate the armature in a growler with a steel the brush ends do not contact the field frame.
strip, such as a hacksaw blade, held on the — If the test lamp lights, the field coils are
armature parallel to the shaft. The steel strip grounded. Replace the field and frame
will vibrate on the area of the short circuit. assembly.
Figure 5—Testing the Armature for Short Circuits Figure 6—Testing the Armature for Grounds
SD STARTER MOTORS 6D2A-5
a Tighten
$ Tighten
a Tighten
SPECIFICATIONS
STARTER
NO-LOAD TEST @ 10 VOLTS
STARTER AMPS RPM SOLENOID
PART NO. SERIES MIN MAX MIN MAX PART NO.
10455053 SD-210 52 76 6000 12,900 1114582
10455013 SD-260 50 62 8500 10.700 1114582
10455050 SD-260 47 70 6500 11,000 1114579
SOLENOID SWITCHES
SWITCH PULL-IN WINDING HOLD-IN WINDING
PART NO. VOLTS AMPS VOLTS AMPS VOLTS
1114520 12 60-85 10 10-20 10
1114578 12 60-85 10 10-20 10
1114579 12 60-85 10 10-20 10
LUBRICATION
Use Delco-Remy DC 33 Lubricant or equivalent.
T2533
28-MT STARTER MOTORS 6D2B-1
SECTION 6D2B
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................6D2B- 1
Starter Motor........................................................................................................................................................6D2B- 1
identification.........................................................................................................................................................6D2B- 1
Diagnosis.................................................................................................................................................................. 6D2B- 2
No-Load Test........................................................................................................................................................6D2B- 2
Disassembly.............................................................................................................................................................6D2B- 3
Introduction.......................................................................................................................................................... 6D2B- 3
Unit Disassembly................................................................................................................................................ 6D2B- 3
Frame, Field, and Brush Holder Group.........................................................................................................6D2B- 5
Gear Reduction and Drive G roup...................................................................................................................6D2B- 5
Driveshaft and Clutch Group........................................................................................................................... 6D2B- 6
Cleaning, Inspection, and Repair........................................................................................................................ 6D2B- 6
Cleaning................................................................................................................................................................ 6D2B- 6
Inspection............................................................................................................................................................. 6D2B- 6
Component Electrical Testing.......................................................................................................................... 6D2B- 7
Repair Procedures.............................................................................................................................................. 6D2B- 8
Armature Bearing Replacement...................................................................................................................6D2B- 8
Center Support Bearing................................................................................................................................ 6D2B- 8
Drive End Housing Bushing......................................................................................................................... 6D2B- 9
Lubrication............................................................................................................................................................ 6D2B- 9
Assembly...................................................................................................................................................................6D2B- 9
Driveshaft and Clutch Group........................................................................................................................... 6D2B- 9
Gear Reduction and Drive G roup...................................................................................................................6D2B-10
Frame, Field, and Brush Holder Group......................................................................................................... 6D2B-10
Unit Assembly......................................................................................................................................................6D2B-11
Testing After Overhaul.......................................................................................................................................6D2B-12
Specifications.......................................................................................................................................................... 6D2B-12
Starter Motors......................................................................................................................................................6D2B-12
Solenoid Switches............................................................................... ...............................................................6D2B-12
Lubrication............................................................................................................................................................ 6D2B-12
Fastener Tightening........................................................................................................................................... 6D2B-12
GENERAL DESCRIPTION
SXARTER M O TO R 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 id f m t ip ip a t io n
driveshaft is driven by the armature shaft gear at a IDENTIFICATION
speed of one driveshaft revolution for each 3.9 revolu- The part number is stamped on a label and attached
tions of the armature. to the field frame (figure 1).
6D2B-2 28-MT STARTER MOTORS
DIAGNOSIS
NO-LOAD TEST 3. Make all connections and disconnections with the
switch open and the carbon pile off.
Before disassembling the starter motor for repair, the
4. If sparking or current flow occurs in the battery
following test should be made.
circuit when connections are being made, the start
NOTICE: N ever operate the starter m otor er motor solenoid switch contacts may be frozen
m ore than 30 s e c o n d s a t a tim e w ithout shut.
pausing to allow it to cool for at least 2 min 5. As the last step in making test connections, ground
utes. O verheating will dam age the starter the negative battery cable securely to a clean met
motor. al ground on the starter motor frame.
6. The carbon pile load is used to adjust operating
Test Connections voltage for comparison with specifications. It may
Connect the starter motor for the test as shown in not be necessary in all cases.
figure 2.
Test Procedure
1. Secure the starter motor in a test stand.
2. Use a momentary contact pushbutton switch in the CAUTION: Keep fingers and tools away from
test circuit that can be released quickly if very high the opening in the drive end housing while
current surges occur. testing. The strong shifting action of the sole
noid could cause personal injury or damage
as the drive pinion moves into the cranking
position and spins.
1. Momentarily close the switch.
• If there is high current flow and the starter
motor fails to operate, release the switch imme
diately. Internal mechanical damage is indicat
ed.
• If there is no current flow and the starter motor
fails to operate, release the switch immediately.
An open circuit is indicated.
• If there is current flow and the starter motor
operates, release the switch and proceed with
the next step.
2. Close the switch and compare the RPM, ammeter,
and voltmeter readings with the specifications at
the end of this section. It is not necessary to obtain
the exact voltage specified as a good reading can
be made by understanding that if the voltage is
slightly higher the RPM will be slightly higher, with
Figure 2—No-Load Test Connections the current remaining basically unchanged. Howev-
28-M T STARTER MOTORS 6D2B-3
er, if the exact voltage is desired, a carbon pile • Grounded armature or fields. Check further
connected across the battery can be used to after disassembly.
reduce the voltage to the specified value as
4. Failure to operate with high current draw indicates:
described in step 3.
3. Close the switch and observe the voltmeter. Adjust • A direct ground in the terminal or fields.
the carbon pile load until the voltmeter reads 10 • Seized bearings. This should have been noted
volts. Record the ammeter and RPM readings. by turning the armature by hand.
Open the switch. 5. Failure to operate with no current draw indicates:
4. Compare the ammeter and RPM readings to those
listed under “Specifications.” If the readings are • Open field circuit. This can be checked after
outside the limits shown, refer to the list below. If disassembly by inspecting internal connections
the readings are within the limits, the starter motor and tracing the circuit with a test lamp.
is operating normally. • Open armature coils. Inspect the commutator
for badly burned bars after disassembly.
Troubleshooting • Broken brush springs, worn brushes. High
insulation between the commutator bars or oth
1. Rated current draw and no-load speed indicates er causes that would prevent good contact
normal condition of the starter motor. between the brushes and commutator.
2. Current flow with the test switch open indicates the
solenoid switch contacts are stuck closed. 6. Low no-load speed and low current draw indicates
3. Low free speed and high current draw indicates: a higher internal resistance due to poor connec
tions, defective leads, dirty commutator, and
• Too much friction. Tight, dirty, or worn bear causes listed under step 5.
ings, bent armature shaft, or loose pole shoes 7. High free speed and high current draw indicates
allowing the armature to drag. shorted fields. If shorted fields are suspected,
• Shorted armature. This can be further checked replace the field coil assembly and check for
on a growler after disassembly. improved performance.
DISASSEMBLY
INTRODUCTION 1. Motor lead on the frame assembly from the sole
noid assembly.
If the motor does not perform to specifications, it may
• Remove the nut from the motor terminal, slip off
need to be disassembled for further testing of the com
the motor lead, and reinstall the nut.
ponents. Normally, the starter motor should be disas
sembled only so far as is necessary to make repair or 2. Two through-bolts.
replacement of parts. The 28-M T components are 3. Two brush plate screws.
shown in figure 3. 4. Commutator end frame and O-ring seal.
Do not attempt to disassemble the following compo
nents that are serviced as assemblies: Important
• Solenoid assembly (19)
• In the following step, take care not to lose the
• Clutch drive assembly (34)
small dowel pin installed between the frame
• Brush holder assembly (7)
assembly and the gear reduction and drive
• Armature assembly (13)
group. The dowel pin is needed for assembly
• Frame and field assembly (15) and must be saved. If it is lost, it must be
As a precaution, it is suggested that safety glasses replaced with a 2-mm x 10-mm (0.079-inch x
be worn when disassembling or assembling the starter 0.394-inch) long pin obtained or manufactured
motor. locally.
5. Frame, field, and brush holder group, dowel pin,
U N IT DISASSEMBLY and O-ring seal.
• The armature assembly may come off with the
Disassemble (Figure 4) frame, field, and brush holder group or may be
* retained by the gear reduction and drive group.
• Clean the outside of the starter housing, removing 6. Armature assembly with bearings.
grease, oil, mud, etc.
• Do not remove the bearings from the armature
• Scribe marks completely down one side of the
assembly unless replacement is required. Refer
starter motor to ensure proper alignment of all
to “Cleaning, Inspection, and Repair.”
components during assembly. Use a colored pencil
or marker that will show on all parts. 7. Solenoid screws.
6D2B-4 28-MT STARTER MOTORS
1. BOLT, THROUGH
2. SCREW, BRUSH PLATE
3. FRAME, COMMUTATOR END
4. SEAL, O-RING (C.E. END)
5. BRUSH (GROUNDED)
6. SCREW, GROUNDED BRUSH 24. PLATE (IF USED)
7. ASSEMBLY, BRUSH HOLDER 25. BOLT, DRIVE HOUSING
8. BRUSH (INSULATED) (SHORT ON SOME MODELS)
9. SCREW, INSULATED BRUSH 26. BOLT, DRIVE HOUSING (LONG)
10. BRUSH (GROUNDED) 27. BRACKET, ARMATURE SUPPORT
11. SPRING, BRUSH 28. WASHER, (FIBER)
12. BEARING, C.E. ARMATURE 29. WASHER, THIN (ONE OR
13. ARMATURE TWO MAY BE USED)
14. BEARING, D.E. ARMATURE 30. WASHER, THICK
15. ASSEMBLY, FRAME AND FIELD 31. SHAFT, DRIVE
16. PIN, DOWEL 32. BEARING, CENTER SUPPORT
17. SEAL, O-RING (FIELD FRAME) 33. SUPPORT, DRIVE SHAFT
18. SCREW, SOLENOID 34. ASSEMBLY, CLUTCH DRIVE
19. ASSEMBLY, SOLENOID 35. RING, STOP
20. LEVER, SHIFT 36. STOP, PINION
21. PLUG, DRIVE HOUSING 37. BUSHING, D.E. HOUSING
22. WASHER, SHIFT LEVER 38. SCREW, SHIFT LEVER
23. NUT, SHIFT LEVER 40. PLUG, BUSHING (IF USED)
V3862
❖ Disassemble (Figure 6)
1. Housing bolts.
2. Armature support bracket.
9 Important
FRAME, FIELD, AND BRUSH • Save the washers to be installed in the same
position and number at assembly.
HOLDER GROUP
4. Drive housing plug and plate.
• Pry out the drive housing plug with a large
* Disassemble (Figure 5)
screwdriver.
Figure 5— Frame, Field, and Brush Holder Group Figure 6—Gear Reduction and Drive Group
6D2B-6 28-M T STARTER MOTORS
Figure 7—Drive Shaft and Clutch Group Figure 8—Removing the Pinion Stop
DRIVESHAFT AND CLUTCH D. Inspect the edges of the shaft groove for burrs
that may have been formed through repeated
GROUP cranking cycles. Such burrs may make removal
Disassembly of the driveshaft and clutch group is not
of the pinion stop and clutch drive assembly
required unless it is necessary to clean, inspect, or
difficult.
replace one or more parts of the group separately.
• If burrs are found, use a file to carefully
Disassemble (Figures 7 and 8)
* remove burrs only, not the base metal. Thor
oughly clean away metal filings.
1. Stop rings and pinion stop.
A. Position the driveshaft and clutch group on a E. Slide the pinion stop off the driveshaft. Discard
work bench with the internal gear end down. the old pinion stop and stop rings. New parts
B. Using an open tube (#2 22 MM) slightly larger must be used at assembly.
then the shaft (#1 14.2 MM), drive the pinion
2. Clutch drive assembly from the driveshaft.
stop toward the clutch drive assembly until it
3. Driveshaft support from the driveshaft.
clears the stop rings (figure 8).
C. Pry the stop rings out of the driveshaft groove • Do not remove the bearing from the driveshaft
and slide them off the end of the shaft, being unless replacem ent is required. Refer to
careful not to scratch the driveshaft. “Cleaning, Inspection, and Repair.”
NOTICE: Do no t clean or im m erse the starter 1. All parts for cracks, distortion, or other structural
m otor parts in grease-dissolving solvents. damage. Replace parts or assemblies that are
Solvents will d issolve the grease packed in cracked, bent, or otherwise damaged.
the drive a s s e m b ly a n d m ay dam age the 2. Threaded parts for stripped, crossed, or otherwise
armature or field coil insulation. damaged threads. Replace the parts with thread
damage that cannot be cleaned up using a suitable
tap or die. Replace any hardware items that have
Clean
damaged threads.
3. Solenoid assembly (19) for cut or torn boot. If the
• All starter motor parts with a clean soft cloth prior boot is damaged, replace the solenoid assembly.
to testing. 4. Clutch drive assembly (34) for the following.
Replace the clutch drive assembly if damaged:
INSPECTION • Pinion gear turns roughly or turns in both direc
Inspection in the following steps refers to visual tions.
inspection of the starter motor parts and assemblies to • Pinion gear teeth are broken or show evidence
determine their serviceability. Electrical tests for certain of step wear.
assemblies are described in “Component Electrical • The shift lever collar shows deep scoring or
Testing.” other damage.
28-M T STARTER MOTORS 6D2B-7
9. Armature assembly (13) for the following: • An extremely high resistance reading indicates
a break or fault in the winding continuity. A very
• Gear teeth that are broken, or that show evi
low resistance reading indicates a short or
dence of step wear or root interference.
ground in the winding circuit. Either condition is
• Rough commutator surface. Polish with No. 400
cause for replacement of the solenoid assem
grit polishing cloth if necessary. Thoroughly
bly.
clean metal dust from between the commutator
bars. If the commutator surface cannot be 2. Check the armature assembly as follows for shorts,
repaired in this manner, replace the armature opens, or grounds.
assembly. Do not turn the commutator in a
lathe. • Rotate the armature in a growler holding a steel
•W o rn commutator. Replace the armature strip such as a hacksaw blade against the
assembly if the commutator outer diameter is armature. If a short circuit is present, the steel
less than 36 mm (1.378 inch) or if the undercut strip will vibrate in that area.
depth at any point is less than 0.2 mm (0.008 • Check the armature for grounds using a
inch). Do not undercut the insulation. self-powered test lamp or ohmmeter. There
should not be any continuity between the arma
10. Driveshaft (31) for the following. Replace the drive ture shaft and any point on the commutator.
shaft if damaged: • Check for opens by visually inspecting the
• Scored or damaged shaft where it turns in the points where the armature conductors join the
bushing (37). commutator. A poor connection often will be
• Internal gear with teeth broken or showing evi indicated by signs of arcing or burning of the
dence of step wear. commutator.
• Damaged spline. The clutch drive assembly • Replace armatures that are shorted, grounded,
must slide smoothly and easily over the full or show evidence of opens.
length of the spline. 3. Check the frame and field assembly for grounds or
opens as follows (figure 10):
COMPONENT ELECTRICAL
A. Visually inspect the field coil connections for
TESTING opens between the field terminal and the con
nection points for insulated brushes on the field
Perform the following electrical tests on the solenoid,
coil straps.
armature, and frame and field assemblies to determine
B. Using a self-powered test lamp or ohmeter,
their serviceability.
check that there is no continuity (no grounds)
1. Using an ohmmeter, check the windings of the between the frame and the field terminal.
solenoid assembly for continuity as follows: C. Replace the frame and field assemblies that
have grounds or opens.
• Check the resistance of the solenoid pull-in and
hold-in windings in series by measuring the
resistance between the motor terminal and the
solenoid case (figure 9). Resistance should be
about 1.95 ohms.
6D2B-8 28-MT STARTER MOTORS
<-— 55 mm ----------
___r m r rn r m
35 mm
r
Figure 10— Frame and Field Assembly Figure 12—Tool for Removing Center Support
Bearing (Side View)
REPAIR PROCEDURES
ARMATURE BEARING REPLACEMENT
If necessary, replace the bearings (12 and 14) or
armature (13) as follows (figure 3).
• Center support bearing (32) from the driveshaft 2. Bushing (37) by pressing it out using a suitable
(31) using a locally fabricated tool as shown in tool.
figures 11, 12, and 13. With the driveshaft in a
suitable support fixture, place the tool bolt ends -►*- Install or Connect (Figure 3)
through the access holes in the wide end of the
driveshaft. Squarely press the bearing off of the 1. New bushing into the drive housing (39) by press
surface on the center shaft. ing it in using a suitable tool.
|-»<-| Install or Connect (Figures 3, 11, 12 and 13) • Press the bushing in until it is flush with the
inside of the housing.
•N e w bearing (32) to the driveshaft (31), using a 2. New plug (40), if used, to drive housing.
locally fabricated tool (open tube) that bears on the
• Stake the housing material over the plug at
bearing inner race only. Press on the bearing until
three places, equally spaced.
the inner race bottoms out against the shoulder on
the driveshaft.
LUBRICATION
DRIVE END HOUSING BUSHING
Armature bearings and the driveshaft support bearing
If necessary, replace the bushing (37) in the drive are permanently lubricated. Do not add lubricant to
housing (39). these bearings. Using Delco Remy lubricant P/N DC 33
or equivalent, lubricate the following areas during
Remove or Disconnect (Figure 3) assembly. Avoid using excessive grease.
• Drive end housing bushing in the drive housing.
1. Plug (40) if present from inside the drive housing • Pivot hole and working surface on the ends of the
(39) by driving it out. Use a file to clean away shift lever.
remnants of the old stake to allow installation of a • Internal gear, shaft, and spline on the driveshaft.
new plug. Clean away any metal shavings.
ASSEMBLY
DRIVESHAFT AND CLUTCH D. Make sure the stop rings (35) (in the driveshaft
groove) are fully seated in the pinion stop
GROUP recess and stake the upper edge of the pinion
If disassembled, position the driveshaft on a work stop (36) over the stop ring (35) at four places,
surface with the internal gear end down. Assemble the equally spaced. Do not allow the staked metal
driveshaft and clutch group as follows: to contact the driveshaft (31).
V Important (Figure 3)
1. Arms on the shift lever with the shift collar onto the
driveshaft and clutch group.
Figure 15— Brush Spring on the Post
2. Assembled shift lever and driveshaft and clutch
group into the drive housing.
A. Align the holes in the driveshaft support with
those in the drive housing (figure 7).
B. Make sure that the driveshaft support is fully
seated in the drive housing and that the
driveshaft bearing remains fully seated in the
driveshaft support.
3. Shift lever screw, washer, and nut.
a Tighten
Tighten Holder
• Drive housing bolts to 8.5 N-m (75 lbs. in.). C. Push the spring fully onto the post and release
the free end to engage the notch in the brush
socket.
FRAME, FIELD, AND BRUSH
HOLDER GROUP
NOTICE: B ru sh le a d s m a y b e d a m a g e d b y
+ 4- Install or Connect (Figures 5, 15, and 16)
excessive handling. Do n o t overflex the leads
near the clip welds or the clips m ay break
off.
NOTICE: For ste p s 3 and 4, refer to NO-
TICE” on page 6D2B-1. 2. Brushes if removed.
HI Tighten SO Tighten
• Brush plate screws to 2.8 N m (25 lbs. in.). • Through-bolts to 8.5 N-m (75 lbs. in.).
9. Motor lead onto the frame and field assembly (fig
8. Through-bolts. ure 5).
A. Install the through-bolts and tighten by hand, • Remove the nut from the terminal on the sole
noid, install the motor lead terminal, and rein
but do not close the gap between the commuta
stall the nut.
tor end frame and frame and field assembly
where the O-ring seal goes. Tighten
B. Roll the O-ring seal back down into its installed St
position between the commutator end frame Solenoid motor terminal nut to 11 N-m (100 lbs.
and the frame and field assembly. in.).
C. Align the timing ribs on the edge of the commu
tator end frame with the timing spots on the TESTING AFTER OVERHAUL
frame and field assembly to ensure proper
After overhaul of the starter motor, perform the
brush alignment (figure 17). Marks are located ‘No-Load Test.”
in two places on the motor, but will only match
one way.
SPECIFICATIONS
STARTER MOTORS
No Load Test @ 10 Volts (Includes Solenoid Current)
Starter AMPS RPM Solenoid
Part No. Series Minimum Maximum Minimum Maximum Part No.
1113296 28-MT 125 190 3000 5600 10456454
SOLENOID SWITCHES
Switch Pull-In Winding Hold-ln Windin 9
Part No. Volts Amps Volts Ohms Amps Volts Ohms
10456454 12 52-59 10 0.17-0.19 12-14 10 0.76-0.81
LUBRICATION
Use Delco-Remy Gear and Shaft Lubricant No. DC 33 or equivalent.
FASTENER TIGHTENING
N-m Lbs. In.
Brush Plate Screws........................................................................................................................................... 2.8 25
Drive Housing Bolts.......................................................................................................................................... 8.5 75
Grounded Brush Screws............................................................................................................................. ..... 1.5 13
Insulated Brush Screws........................................................ ...................... ............................................... ..... 1.5 13
Shift Lever N ut............................................................................................................................................. ..... 4.5 40
Solenoid Screws........................................................................................................................................... ..... 2.8 25
Solenoid Motor Terminal Nut........................................................................................................................... 11 100
Through Bolts..................................................................................................................................................... 8.5 75
T3028
CS-144 GENERATOR 6D3A-1
SECTION 6D3A
CS-144 GENERATOR
NOTICE: When fasteners are removed, always reinstall them at the sam e location from which they were
removed. If a fastener needs to be replaced, u se the correct part num ber fastener for that application. If
the correct part num ber fastener is n o t available, a fastener o f equal size and strength (or stronger) m ay
be used. Fasteners that are n ot reused, and those requiring thread locking com pound will be called out.
The correct torque value m u st b e u sed when installing fasteners that require it. If the above conditions
are not followed, parts or sy ste m damage could result.
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................. 6D3A-1
Delco Remy CS-144 Generator.......................................................................................................................... 6D3A-1
Operating Principles......................................................................................................................................... 6D3A-1
Diagnosis.....................................................................................................................................................................6D3A-2
Generator Output Test......................................................................................................................................... 6D3A-2
Disassembly............................................................................................................................................................... 6D3A-3
Drive End Frame................................................................................................................................................... 6D3A-3
Slip Ring End Frame............................................................................................................................................ 6D3A-3
Inspection and Repair............................................................................................................................................. 6D3A-4
Cleaning and Inspection......................................................................................................................................6D3A-4
Electrical Tests.......................................................................................................................................................6D3A-5
Rotor Field Winding Tests.............................................................................................................................. 6D3A-5
Stator Test........................................................................................................................................................... 6D3A-5
Rectifier Bridge Test............ ............................................................................................................................ 6D3A-5
Regulator............................................................................................................................................................. 6D3A-6
Assembly.....................................................................................................................................................................6D3A-6
Slip Ring End Frame............................................................................................................................................ 6D3A-6
Drive End Frame....................................................................................................................................................6D3A-7
Main Assembly.......................................................................................................................................................6D3A-7
Specifications............................................................................................................................................................ 6D3A-8
Generator Specifications.....................................................................................................................................6D3A-8
Fastener Tightening Specifications.................................................................................................................. 6D3A-8
Special Tools............................................................................................................................................................. 6D3A-8
GENERAL DESCRIPTION
DELCO REMY CS-144 switches rotor field current on and off at a fixed fre
quency of about 400 cycles per second to help control
GENERATOR radio noise. By varying on-off time, correct average field
The CS-144 generator with integral regulator shown current for proper system voltage control is obtained. At
in figure 1 features a high ampere output per pound of high speeds, on-time may be 10 percent and off-time
weight. It does not use a diode trio. The delta stator, 90 percent. At low speeds, with high electrical loads,
rectifier bridge, and rotor with slip rings and brushes, on-off time may be 90 percent and 10 percent respec
are electrically similar to other CS-series generators. tively.
CS stands for Charging System, and 144 indicates the A basic wiring circuit for the “PLIS” regulator is
outside diameter of the stator laminations in millimeters. shown in figure 2. The “P” terminal connects to the
The bearings are sealed with lifetime lubrication in both stator. The “S” terminal may be connected externally to
end frames. No periodic maintenance is required. the battery to monitor voltage and make sure the regu
OPERATING PRINCIPLES lator maintains an adequate voltage level to charge the
Regulator voltage setting varies with temperature and battery. If the “S” terminal is not connected externally,
limits system voltage by controlling rotor field current. integrated circuits in the regulator are used for sensing
When the field current is ON, the regulator actually voltage.
6D3A-2 CS-144 GENERATOR
TO :
4J -i
r~ p~
REaULATOR O
----E* I
I____ ___ J
RECTIFIER
BRIDGE 2 Ui l i
\ rr
m *
- - - - --- -- ----- -------------
Figure 1—CS-144 Generator Figure 2—Generator Schematic
Both the “L” and “I” terminals serve to turn on the to the “L”terminal. When used, the “L” terminal must be
regulator and allow field current to flow when the switch connected through an external resister, such as the
is closed. The “I” terminal may be connected either charging system indicator lamp. When a generator fault
directly to the switch, or through a resistor. The “I” is detected, (voltage to high or to low, or no rotation),
circuit may be used with or without anything connected the regulator grounds the “L” terminal and activates the
to the “L” circuit and with or without anything connected indicator lamp.
DIAGNOSIS
GENERATOR OUTPUT TEST to the battery positive terminal (through the amme
ter) and that the battery and generator are properly
This test requires a both standard test stand to oper grounded.
ate the generator, and a fully charged battery. 2. Connect a 30 to 500-ohm resistor between the
positive battery terminal and the “L” terminal on the
1. Install and connect the generator to the test stand
generator.
as shown in figure 3. The ground polarity of the
3. Operate the generator through the test stand,
generator and the battery must be the same. The
increasing speed slowly, and observe the voltage.
carbon pile must be turned off to begin the test. Be
4. If the voltage is uncontrolled and increases above
sure that the generator BAT terminal is connected
16 volts, the rotor field is shorted, the regulator is
not working properly, or both. A shorted rotor field
coil can cause problems in the regulator.
5. If the voltage is below 16 volts, increase speed and
adjust the carbon pile to obtain maximum amper
age output. Maintain the voltage above 13 volts.
6. If the output is within 15 amperes of the rated out
put, the generator is good.
7. If the output is not within 15 amperes of the rated
output, replace the generator.
DISASSEMBLY
DRIVE END FRAME NOTICE: On m odels with a slip ring en d ball
bearing on the rotor shaft, this bearing m u st
be replaced with a new bearing any time the
Remove or Disconnect (Figures 4, 5, 6 and 7) two halves o f the generator are separated. If
not replaced, the bearing m ay bind and fail
due to distortion o f its outer tolerance rings.
Tool Required: This d o es n ot apply to roller-type slip ring
J 28509-A Bearing Remover en d frame bearings.
• Scribe a mark to help locate the frame end parts in
the same position during assembly. • Place the rotor in a vise and tighten only
enough to permit removal of the pulley nut
1. Four through-bolts.
2. Rotor and drive end frame assembly from the slip NOTICE: The rotor m ay be distorted if the
ring end (SRE) frame assembly. vise is overtightened.
Figure 5—CS-144 Components Figure 6— Removing the Slip Ring End Bearing
6D3A-4 CS-144 GENERATOR
Figure 7— Drive End Frame Components Figure 8—Slip Ring End Frame with Stator
Removed
5. BAT terminal nut from the insulated heat sink (fig
ure 9).
6. Two screws and washers from the grounded heat
sink.
7. Capacitor and rectifier bridge from the frame (figure
9).
8. “BAT” terminal from the outside of the frame.
ELECTRICAL TESTS
Except as stated, make the following tests with an
ohmmeter on the low range scale.
STATOR TEST
Test the stator with a self-powered test lamp or an
ohmmeter (figure 12). If the ohmmeter reads low, or if
the lamp lights when connected from any stator lead to
bare metal on the stator frame, the stator is grounded.
An ohmmeter cannot be used to test the delta stator
for shorts or opens. Noticeable discoloration at any
place on the assembly usually indicates a problem in
the stator windings.
Figure 12—Testing the Stator For Grounds Figure 13— Rectifier Bridge Test
Observe the ohmmeter reading and reverse the lead Some digital ohmmeters cannot be used to test
connectors to the grounded heat sink and the same diodes in the rectifier bridge. Consult the ohmmeter
metal clip. If both readings are the same, replace the manufacturer to determine your ohmmeter capabilities.
rectifier bridge. A good rectifier bridge will give one high REGULATOR
and one low reading. Repeat this procedure between The regulator cannot be tested outside of the gener
the grounded heat sink and the other two terminals, and ator. If the rotor, stator, and rectifier bridge are OK, but
between the insulated heat sink and each of the three the generator still produces more than 16 volts or does
terminals. This makes a total of six tests, with two read not produce within 15 amperes of the rated output dur
ings taken for each test. ing a generator output test, replace the regulator.
ASSEMBLY
SLIP RING END FRAME A. File the jagged edges down to the level of the
surrounding material. Keep loose particles away
Remove or Disconnect from the brush slots.
B. Blow away any dust.
1. Two locators from the brush holder with needle
nose pliers or side cutters. -►4- Install or Connect (Figures 4, 5, 8, 9, 10 and
14)
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
10480022 CS-144 2.1-2.4 5.0-5.7 124
10480023 CS-144 2.1-2.4 5.0-5.7 145
10479959 CS-144 2.1-2.4 5.0-5.7 124
SPECIAL TOOLS
DISTRIBUTORS 6D4A-1
SECTION 6D4A
DISTRIBUTORS
NOTICE: When fasteners are removed, always reinstall them at the sa m e location from which they were
removed. If a fastener needs to be replaced, u se the correct part num ber fastener for that application. If
the correct part num ber fastener is n ot available, a fastener o f equal size and strength (or stronger) m ay
be used. Fasteners that are n o t reused, and those requiring thread locking com pound will be called out.
The correct torque value m u st be u sed when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
SUBJECT PAGE
General D escrip tio n ....................................................................................................................................................... 6D4A-1
Delco Remy Distributors........................................................................................................................................... 6D4A-1
Identification.............................................................................................................................................................6D4A-1
Ignition C o il............................................................................................................................................................... 6D4A-1
Ignition Control M o d u le ........................................................................................................................................6D4A-1
Pole Piece and Coil Assem bly............................................................................................................................6D4A-2
D isassem bly................................................................................................................................................................. 6D4A-2
Inspection and Electrical T e s ts ..............................................................................................................................6D4A-2
A s s em b ly.......................................................................................................................................................................6D4A-3
Special T o o ls ....................................................................................................................................................................6D4A-4
GENERAL DESCRIPTION
DELCO REMY DISTRIBUTORS The distributor uses an internal magnetic pickup
assembly that consists of a permanent magnet, pole
Distributors with separate coils and sealed connectors piece with internal teeth, and pickup coil. When the
are used on light duty truck engines (figure 1). The rotating teeth of the timer core line up with the teeth of
ignition coil connects to the distributor cap through a the pole piece, voltage is induced in the pickup coil.
high tension wire. This voltage signals the ignition control module (ICM) to
trigger the primary ignition circuit. Current flow in the
primary circuit is interrupted and up to 35,000 volts is
induced in the ignition coil secondary winding. This volt
age is directed through the secondary ignition circuit to
fire the spark plugs.
IDENTIFICATION
The seven-digit part number is stamped into the dis
tributor housing.
IGNITION COIL
The coil is built like a transformer with the winding
surrounded by a laminated iron frame. It generates a
high secondary voltage (up to 35,000 volts) when the
primary circuit is broken. It connects to the distributor
by a high tension wire.
IGNITION CONTROL MODULE
The ignition control module (ICM) is a solid state unit
containing many circuits. These circuits control spark
triggering, switching, current limiting, dwell control, and
distributor pickup. The vehicle’s computer sends signals
to the module to control dwell and spark timing. The
module may have seven or eight terminals, depending
on the ignition system.
6D4A-2 DISTRIBUTORS
DISASSEMBLY
+-► Remove or Disconnect (Figures 2 through 4)
7. Shield.
8. Pickup coil connector from the module. Figure 3— V8 Engine Distributor Components
• Lift the locking tab with a screwdriver.
9. Pickup coil.
10. Two screws holding the module to the housing.
11. Module.
INSPECTION AND
ELECTRICAL TESTS
Inspect
HI Measure
Tools Required:
J 24642-F Module Tester
1. Resistance of the pickup coil with an ohmmeter.
A. Connect an ohmmeter to either pickup coil lead
and the housing as shown in figure 5, step 1.
The reading should be infinite. If not, replace
the coil.
B. Connect an ohmmeter to both pickup coil leads
as shown in figure 5, step 2. Flex the leads by
hand at the coil and the connector to locate any
intermittent opens. The ohmmeter should read
a constant value in the 500 to 1500 ohm/range.
If not, replace the coil.
2. Electrical performance of the module. The module
can only be checked with an approved module tes
ter, such as J 24642-F. Follow the directions exact
ly that come with the tester.
3. Resistance of the ignition coil with an ohmmeter.
A. Connect the ohmmeter as shown in figure 6,
step 1. Use the high scale. The reading should
be infinite. If not, replace the coil.
B. Connect the ohmmeter as shown in step 2. Use
the low scale. The reading should be very low
or zero. If not, replace the coil.
C. Connect the ohmmeter as shown in step 3. Use
the high scale. The meter should not read infi
nite. If it does, replace the coil.
ASSEMBLY
-►«- Install or Connect (Figures 2 through 4)
SPECIAL TOOLS
1. MODULE TESTER
2906r5021
HIGH VOLTAGE SWITCH 6D4B1-1
SECTION 6D4B1
NOTICE: When fasteners are removed, always reinstall them at the sa m e location from which they were
removed. If a fastener n eed s to be replaced, u se the correct part num ber fastener for that application. If
the correct part num ber fastener is n ot available, a fastener o f equal size and strength (or stronger) m ay
be used. Fasteners that are not reused and those requiring thread locking com pound will be called out.
The correct torque value m u st be u sed when installing fasteners that require it. If the above conditions
are not followed, parts or sy ste m damage could result.
CONTENTS
SUBJECT PAGE
General Description............................................................................................................................................... 6D4B1-1
Identification.....................................................................................................................................................6D4B1-1
Ignition Coil/Coil Driver................................................................................................................................. 6D4B1-1
Secondary Wires............................................................................................................................................. 6D4B1 -2
Camshaft Position Sensor................................................................... ........................................................ 6D4B1-2
Crankshaft Position Sensor..........................................................................................................................6D4B1-2
Disassembly.........................................................................................................................................................6D4B1-2
Inspection and Electrical Tests.......................................................................................................................6D4B1-3
Ignition Coil Test............................................................................................................................................. 6D4B1-3
Assembly.............................................................................................................................................................. 6D4B1-3
GENERAL DESCRIPTION
The high voltage switch (HVS) (figure 1) system position sensor. The ignition system is controlled by the
includes the camshaft position sensor, ignition coil, sec vehicle control module (VCM-A). The VCM-A monitors
ondary wires, spark plugs, knock sensor and crankshaft information from various engine sensors, computes the
desired spark timing and controls the dwell and firing of
the ignition coil via an ignition control line to the coil
driver. For information on the high value ignition system
diagnostics, refer to the Driveability, Emissions and
Electrical Diagnosis Manual.
The HVS connects the ignition coil and spark plugs
through secondary wires. The rotor directs the spark to
the appropriate cylinder. The HVS has an internal cam
sensor that connects to the VCM through the primary
engine harness and provides cylinder identification.
IDENTIFICATION
The part number is etched into the plastic base (next
to the high tension wire plug).
SECONDARY WIRES
The secondary wires carry high voltage between the
ignition coil, HVS, and spark plugs. The secondary wire
connections form a tight seal that prevents voltage
arching.
DISASSEMBLY
NOTICE:The high voltage sw itch gear and Figure 3—Rotor Mounting Position
rotor can be installed in multiple positions.
Make sure to mark the gear, shaft and rotor
m ounting holes for sam e positioning on reas
sem bly. If the gear is installed 180 degrees
o ff or the rotor is installed in the wrong
m ounting holes, a no start condition m ay
occur. P rem ature wear a n d dam age m a y
result.
_
NOTICE: Failure to ke e p cleaning a g e n ts
away from the cam shaft position sen so r m ay
Figure 2—High Voltage Switch Components result in premature failure.
HIGH VOLTAGE SWITCH 6D4B1-3
INSPECTION AND
ELECTRICAL TESTS
I? Inspect
Measure
ASSEMBLY
Install or Connect (figures 2, 3, 4, 6, 7, and 8)
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
Borg-Warner T5 Manual Transmission...................................................................................................................7B6-1
New Venture Gear NV3500 Manual Transmission.............................................................................................. 7B7-1
New Venture Gear NV4500 Manual Transmission.............................................................................................. 7B8-1
New Process 233 Transfer Case............................................................................................................................. 7D1-1
New Process 241 Transfer Case............................................................................................................................. 7D2-1
New Process 231 Transfer Case............................................................................................................................. 7D3-1
Borg-Warner 4401 Transfer Case............................................................................................................................ 7D4-1
Borg-Warner 4472 Transfer Case............................................................................................................................ 7D5-1
Borg-Warner 4470 Transfer Case............................................................................................................................ 7D6-1
SBION
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-1
SECTION 7A-14B
HYDRA-MATIC 4L60-E
AUTOMATIC TRANSMISSION UNIT REPAIR
RPO M30
NOTICE: W hen fasteners are rem oved, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part num ber fastener for that application. If the
correct part num ber is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking com pound will be called out. The correct torque value
must be used when installing fasteners that require it. If the above conditions are not followed, parts or system
damage could result.
CONTENTS
Transmission D isassem b ly ...................... .... 7A-14B-2 Input Internal Gear and Output S h a ft.... 7A-14B-23
General Service In fo rm atio n ............... .....7A-14B-2 Input Carrier and Sun G e a r .......... ......... 7A-14B-24
2-4 Servo A ssem bly............................... .... 7A-14B-2 Input Clutch A ssem b ly .................. ......... 7A-14B-25
Servo Pin L e n g th ........................................ 7A-14B-3 Check Valve Retainer and Ball Assembly -
Speed Sensor and Case E xtension ...... .....7A-14B-5 Replacement P ro ced u res.......... ......... 7A-14B-26
Pan and Filter A ssem bly....................... .... 7A-14B-6 Forward Clutch Sprag A ssem bly.. ......... 7A-14B-32
Valve Body and Wiring H a rn e ss ........ .....7A-14B-6 Forward Clutch Piston Travel
Transmission End Play C h e c k ............. .....7A-14B-9 C heck............................................. .........7A-14B-34
Oil Pump A ssem bly............................... .... 7A-14B-9 3-4 Clutch A sse m b ly ...................... ......... 7A-14B-35
2-4 Band, Reverse Input Clutch, 3-4 Clutch Piston Travel Check ... ......... 7A-14B-35
Input Clutch and Input G ear Set .... ... 7A-14B-10 Clutch Air C h e c k ............................. ......... 7A-14B-35
Reaction Gear S e t.......................................7A-14B-11 Turbine Shaft S eals......................... ......... 7A-14B-36
Lo and Reverse Clutch P a r ts ............... ... 7A-14B-12 Reverse Input Clutch Assembly ... ......... 7A-14B-37
Inner M anual L in k a g e .......................... ... 7A-14B-13 Reverse Input Clutch Backing Plate
Manual Shaft Seal R eplacem ent......... ... 7A-14B-13 S election....................................... ......... 7A-14B-39
Component Repair and Reverse Input and Input Clutches ......... 7A-14B-40
Transmission R eassem b ly ................... ... 7A-14B-14 2-4 Band A sse m b ly ........................ ......... 7A-14B-41
Case A sse m b ly ....................................... ... 7A-14B-14 Oil Pump A ssem bly........................ ......... 7A-14B-41
C a s e ........................................................... ... 7A-14B-14 Oil Pump B o d y ................................ .........7A-14B-41
Third Accum ulator Retainer and Oil Pump Cover (D isassem ble).... ......... 7A-14B-42
Ball A sse m b ly ................................... ... 7A-14B-15 Oil Pump Body (A ssem b le)......... ......... 7A-14B-44
Retainer and Ball Assembly Leak Oil Pump Cover (A ssem b le)........ ......... 7A-14B-44
Check P ro c e d u re ............................... ... 7A-14B-15 Oil Pump Cover and B o d y ........... ......... 7A-14B-45
Replacem ent Procedure - Third Accum ulator Transmission End Play C h e c k ...... ......... 7A-14B-46
Retainer and Ball A ssem bly ............ ... 7A-14B-15 Valve Body and Associated Parts .......... 7A-14B-49
Lo and Reverse Clutch P is to n ............. ... 7A-14B-16 Control Valve A ssem b ly ................ .........7A-14B-50
Parking P a w l......................................... ... 7A-14B-17 2-4 Servo A ssem bly..................................7A-14B-55
Reaction Internal Gear and Speed Sensor and Case Extension ......... 7A-14B-58
Carrier A ssem bly............................... ... 7A-14B-17 Torque Converter A ssem b ly...................7A-14B-59
Reaction Internal Gear and S u p p o rt... ... 7A-14B-18 Cross S ectio n ..............................................7A-14B-61
Lo and Reverse Clutch Spacer Plate Disassem bled V ie w s........................... .........7A-14B-62
S election.............................................. ... 7A-14B-18 Seal and Bearing L o c a tio n s.............. .........7A-14B-71
Lo and Reverse Clutch Support Bushing L o catio n s.............................. .........7A-14B-72
A ssem b ly ............................................. ... 7A-14B-21 Torque S pecifications..................................7A-14B-73
Reaction Sun Gear and S h e ll................... 7A-14B-22 Bushing Replacem ent
Input Internal Gear and Procedure........................................... .........7A-14B-74
Reaction S h a ft....................................... 7A-14B-22 Special Tools..................................................7A-14B-78
Internal Transmission Speed Sensor
R o to r..................................................... ... 7A-14B-23
7A-14B-2 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR
|ig | Clean
□ Remove or Disconnect
• Torque Converter (1).
Install or Connect
E Remove or Disconnect
• Drain the transm ission fluid out case extension
by rotating transm ission so bell housing is up.
11|| Measure
Figure 3
1. Install J 33037 as shown with apply pin (13). PIN IS PRESET AT FACTORY AND MUST NOT BE
READJUSTED
2. Install servo cover retaining ring (29) to secure
tool. 2-4 SERVO PIN SELECTION
3. A pply 11 N»m (98 lb. in.) torque.
PIN LENGTH PIN I.D.
4. If white line “A ” appears in gage slot “B ” pin
length is correct. MM INCH
5. Use pin selection chart to determ ine correct pin 65.82-66.12 2.59-2.60 1 GROOVE
length if new pin is needed. 67.23-67.53 2.65-2.66 2 GROOVES
68.64-68.94 2.70-2.71 NO GROOVE
RH0102-4L60-E
|m | Remove or Disconnect
Figures 4 and 5
1. 4th apply piston (25).
2. Servo return spring (12).
3. Servo pin retainer ring (24), w asher (23) and
apply pin spring (22).
4. 2nd apply piston pin (13).
5. Install J 22269-01.
6. Retainer ring (14).
7. Cushion spring retainer (15) and cushion spring
(16).
ILL.
NO. DESCRIPTION
12 SPRING, SERVO RETURN
13 PIN, 2ND APPLY PISTON
14 RING, RETAINER (2ND APPLY PISTON)
15 RETAINER, SERVO CUSHION SPRING
16 SPRING, SERVO CUSHION
17 PISTON, 2ND APPLY
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER)
19 RING, OIL SEAL (2ND APPLY PISTON - INNER)
20 HOUSING, SERVO PISTON (INNER)
21 SEAL, O-RING
22 SPRING, SERVO APPLY PIN
23 WASHER, SERVO APPLY PIN
24 RING, RETAINER (APPLY PIN)
25 PISTON, 4TH APPLY
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER)
27 SEAL, O-RING (2-4 SERVO COVER)
28 COVER, 2-4 SERVO
29 RING, SERVO COVER RETAINING
RH0104-4L60-E
[g | Clean
• Exposed ends o f bottom pan screws and spray
w ith penetrating oil.
F ig u re s 9 a n d 10
|<—►
[ Remove or Disconnect
B Remove or Disconnect
Figures 11 through 14
1. Rem aining valve body bolts (62).
2. M anual valve link (89).
3. Control valve assem bly (60). 43 PIN, ACCUMULATOR PISTON
44 PISTON, 3-4 ACCUMULATOR
4. Bolts (58 and 59), accum ulator cover (57),
46 SPRING, 3-4 ACCUMULATOR
piston (56, spring (54) and spring (54A). 47 GASKET, SPACER PLATE TO CASE
5. Bolts (77) and plate (53). 48 PLATE, VALVE BODY SPACER
52 GASKET, SPACER PLATE TO VALVE BODY
6. Spacer plate (48) and spacer plate gaskets (47 53 PLATE, SPACER PLATE SUPPORT
and 52). 54 SPRING, 1-2 ACCUMULATOR
7. Spring (46), piston (44), and pin (43). 54A SPRING, 1-2 ACCUMULATOR (INNER)
56 PISTON, 1-2 ACCUMULATOR
• Seven checkballs are located under the 57 COVER AND PIN ASSEMBLY, 1-2 ACCUMULATOR
valve body and one is located in the case. 58 BOLT, ACCUMULATOR COVER
The large copper flash colored ball is #1 59 BOLT, ACCUMULATOR COVER
checkball (91). 77 BOLT, SPACER PLATE SUPPORT RH0111-4L60-E-R1
#8 #4
Tools Required:
J 24773-A Oil Pum p Rem over
J 25022-A End Play A daptor (245 m m)
J 34725 End Play A daptor (298 mm)
J 25025-7A Post
Dial indicator
As a diagnostic aid, transmission end play should
be checked prior to rem oving the internal parts. If the
end play is not within specifications, you should watch
for possible w orn or m isassem bled parts during
disassembly.
Measure
Remove or Disconnect
Figures 18 and 20
1. Reverse input clutch (605) and input clutch
(621) together.
• Grasp the turbine shaft and lift.
2. Band anchor pin (41).
3. The 2-4 band assem bly (602).
4. Input sun gear (658).
Install or Connect
B
Figures 19 and 20
• J 29837 as shown.
| V | Important
J 29837
8 CASE, TRANSMISSION
687 SHAFT, OUTPUT S H 0118-4L60-E
2 BOLT, PUMP TO CASE
3 O-RING, PUMP TO CASE BOLT
4 PUMP ASSEMBLY, OIL Figure 19 Output Shaft Support Fixture
5 SEAL, OIL (PUMP TO CASE)
6 GASKET, PUMP COVER TO CASE
8 CASE, TRANSMISSION |<—»| Remove or Disconnect
41 PIN, BAND ANCHOR
601 WASHER, THRUST (PUMP TO DRUM) Figure 20
602 BAND ASSEMBLY, 2-4
605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT 1. R etaining ring (661) with J 34627. D o not
CLUTCH overexpand the ring.
621 HOUSING AND SHAFT ASSEMBLY, INPUT
6 5 8 GEAR, INPUT SUN RH0117-4L60-E 2. Input carrier assem bly (662).
Figure 18 Input Clutch Removal
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-11
8 CASE, TRANSMISSION
661 RET, OUTPUT SHAFT TO INPUT CARRIER
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
REACTION SHAFT)
RH0119-4L60-E
Tools Required:
J 34627 Snap Ring R em over/Installer
J 23327 Clutch Spring C om pressor
[~f~| Important
8 CASE, TRANSMISSION
664 GEAR, INPUT INTERNAL
666 SHAFT, REACTION CARRIER
669 WASHER, THRUST (REACTION SHAFT/SHELL)
670 SHELL, REACTION SUN
673 GEAR, REACTION SUN
674 WASHER, THRUST (RACE/REACTION SHELL)
675 RACE, LO AND REVERSE ROLLER CLUTCH
676 RING, LO AND REVERSE SUPPORT TO CASE RETAINER
678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
679 SUPPORT ASM., LO AND REVERSE CLUTCH
680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
SUPPORT RETAINER)
681 CARRIER ASSEMBLY, REACTION
682A PLATE, LO AND REVERSE CLUTCH (WAVED) 8 CASE, TRANSMISSION
682B PLATE, SPACER LO AND REVERSE CLUTCH (SELECTIVE) 693 RING, LO AND REVERSE CLUTCH RETAINER
682C PLATE ASSEMBLY, LO AND REVERSE CLUTCH (FIBER) 694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
682D PLATE, LO AND REVERSE CLUTCH (STEEL) 695 PISTON, LO AND REVERSE CLUTCH RH0121-4L60-E
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
SUPPORT)
684 GEAR, INTERNAL REACTION Figure 22 Lo and Reverse Snap Ring Removal
685 SUPPORT, INTERNAL REACTION GEAR
692 BRG., REACTION GEAR SUPPORT TO CASE
693 RING, LO AND REVERSE CLUTCH RETAINER
694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
695 PISTON, LO AND REVERSE CLUTCH
697 DEFLECTOR, OIL (HIGH OUTPUT MODELS ONLY)
RH0120-4L60-E
A
A APPLY AIR PRESSURE HERE TO REMOVE LO AND
REVERSE PISTON FROM THE CASE
693 RING, LO AND REVERSE CLUTCH RETAINER
694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH 78 PLUG, STEEL CUP
695 PISTON, LO AND REVERSE CLUTCH 79 SHAFT, PARKING BRAKE PAWL
RH0122-4L60-E 80 SPRING, PARKING PAWL RETURN
81 PAWL, PARKING BRAKE
Figure 23 Lo and Reverse Piston Removal 82 SEAL, MANUAL SHAFT
83 RETAINER, MANUAL SHAFT
84 SHAFT, MANUAL
85 ACTUATOR ASSEMBLY, PARKING LOCK
Inner Manual Linkage 86 BRACKET, PARKING LOCK
87 BOLT, PARKING LOCK BRACKET
Figure 24 88 LEVER, INSIDE DETENT
89 LINK, MANUAL VALVE
|<-»| Remove or Disconnect 90 NUT, HEX HEAD
RH0123-4L60-E
1. Inside m anual shaft nut (90).
2. M anual shaft (84) and m anual shaft retainer Figure 24 Parking Linkage
(83).
3. Parking lock actuator assem bly (85) and inside
detent lever (88) Manual Shaft Seal Replacement
Figure 25
B Remove or Disconnect
• M anual shaft seal (82).
- Pry out with a screwdriver.
82
A
84.
8 CASE, TRANSMISSION
82 SEAL, MANUAL SHAFT
84 SHAFT, MANUAL RH0124-4L60-E
B Install or Connect
F ig u re 3 2
I 693
Tools Required:
J 34627 Snap Ring R em over/Installer 8 CASE, TRANSMISSION
693 RING, LO AND REVERSE CLUTCH RETAINER
J 23327 Clutch Spring Com pressor 694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
695 PISTON, LO AND REVERSE CLUTCH
696 SEAL, TRANSMISSION (LO AND REVERSE CLUTCH -
jT§] Inspect
OUTER, CENTER, INNER) R H0129-4L60-E
F ig u re 3 1
Figure 31 Lo and Reverse Piston
• Lo and reverse piston (695) for:
- Porosity or damage.
- Ring groove damage.
• Piston seals (696) for nicks or cuts.
• Spring assem bly (694) for damage.
• Retainer ring (693) overstressed.
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-17
Parking Pawl
Figure 33
[y | Inspect
• Parking pawl (81) for cracks, burrs, or damage.
• Parking paw l return spring (80) for distortion
or damage.
• Parking pawl pivot shaft (79) for dam age and
freeness o f fit with the parking pawl.
|-n-| Install or Connect
Figure 33
8 CASE, TRANSMISSION 1. Parking paw l (81) and parking pawl return
693 RING, LO AND REVERSE CLUTCH RETAINER
694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
spring (80) into the case.
695 PISTON, LO AND REVERSE CLUTCH DUni 2. Parking pawl pivot shaft (79) into the parking
paw l (81) and the case.
Figure 32 Installing Lo and Reverse Snap Ring • Check for proper operation.
3. Retaining plug (78) into the case.
• C oat the plug w ith Loctite® sealant or
equivalent and install it with a ham m er and
punch.
Inspect
• Reaction internal gear (684) and support (685)
for:
- Proper assembly.
- Stripped splines.
- Cracks.
- Teeth or lug damage.
- Thrust bearing assem blies (683 and 692)
for damage.
• Lo and reverse clutch plates (682) for:
- C om position m aterial wear, heat damage,
or delam ination.
- H eat dam age or surface finish dam age to
steel plates.
78 PLUG, STEEL CUP
• Reaction carrier assem bly (681) for:
79 SHAFT, PARKING BRAKE PAWL - Pinion gear damage.
80 SPRING, PARKING PAWL RETURN - Excessive pinion w asher wear.
81 PAWL, PARKING BRAKE
82 SEAL, MANUAL SHAFT - End play exceeding 0.61 m m (0.024 inch).
83 RETAINER, MANUAL SHAFT - Proper pinion staking.
84 SHAFT, MANUAL
85 ACTUATOR ASSEMBLY, PARKING LOCK - Keystoned pinion gears (pinions m ust turn
86 BRACKET, PARKING LOCK freely).
87 BOLT, PARKING LOCK BRACKET
- D am aged or worn thrust bearing.
88 LEVER, INSIDE DETENT
89 LINK, MANUAL VALVE - To check the captive thrust bearing in the
90 NUT, HEX HEAD carrier for wear, place a bushing or an
R H0123-4L60-E
output shaft sleeve on the bearing race (do
not contact the pinion gears) and turn it
Figure 33 Parking Pawl Installation
w ith th e p a lm o f y o u r h a n d . A n y
im p erfectio n s w ill be felt th ro u g h the
bushing.
7A-14B-18 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR
• R e ta in w ith T ra n s je l™ J 3 6 8 5 0 o r
equivalent.
2. Reaction internal gear and support (684 and
685) onto the bearing as shown.
3. R eactio n c a rrie r to sup p o rt th ru st b earin g
assem bly (683) onto the support (685).
• Outer bearing race goes toward the support.
4. Reaction carrier (681) onto the thrust bearing.
8 CASE, TRANSMISSION
681 CARRIER ASSEMBLY, REACTION
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER./
SUPPORT)
685 SUPPORT, INTERNAL REACTION GEAR
662 CARRIER ASSEMBLY, INPUT (COMPLETE) 692 BRG., REACTION GEAR SUPPORT TO CASE
690 SLEEVE, OUTPUT SHAFT S H 0133-4L60-E
R H0132-4L60-E
682C
682D
682A
WAVED 679 SUPPORT ASM., LO AND REVERSE CLUTCH
682A PLATE, LO AND REVERSE CLUTCH (WAVED)
682B PLATE, SPACER LO AND REVERSE CLUTCH (SELECTIVE)
682C PLATE ASSEMBLY, LO AND REVERSE CLUTCH (FIBER)
STACK UP FOR 682D PLATE, LO AND REVERSE CLUTCH (STEEL)
MEASURING
R H0134-4L60-E
1.75mm
i L / \ 1l r L A I o 1fc t L o
(.069”)
R H0135-4L60-E
R H0136-4L60-E
8 CASE, TRANSMISSION
682 PLATE ASSEMBLY,
LO AND REVERSE CLUTCH
8 CASE, TRANSMISSION
681 CARRIER ASSEMBLY, REACTION
682 PLATE ASSEMBLY, LO AND REVERSE CLUTCH
682A PLATE, LO AND REVERSE CLUTCH (WAVED)
682B PLATE, SPACER LO AND REVERSE CLUTCH
(SELECTIVE)
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
RH0137-4L60-E SUPPORT)
684 GEAR, INTERNAL REACTION
685 SUPPORT, INTERNAL REACTION GEAR
Figure 40 Lo and Reverse Clutch Plates Properly 692 BRG., REACTION GEAR SUPPORT TO CASE
Installed 697 DEFLECTOR, OIL (HIGH OUTPUT
MODELS ONLY) RH0138-4L60-E
1. Inner race (675) from the support assembly. 1. Roller clutch assem bly (678) into the cam and
support assem bly (679).
2. One retainer ring (677).
2. Support and roller assem bly into the case with
3. Roller clutch assem bly (678).
the hub down.
3. Inner race (675) into the roller assembly.
• Turn inner race (675) while inserting.
A. Push down for full engagem ent.
B. Bottom tangs will be flush w ith carrier
hub when properly installed.
C. C heck for proper operation by rotating
the inner race as shown in Figure 42.
4. Support retainer spring (680) into the case.
• Insert betw een the case lug and the one
open notch in the support.
[jy | Inspect
Figure 42
• Inner race (675) for dam age and surface finish. 8 CASE, TRANSMISSION
678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
• R oller clutch assem bly (678) for: 679 SUPPORT ASM., LO AND REVERSE CLUTCH
- D am aged rollers. 680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
- Broken springs. SUPPORT RETAINER) RH0141-4L60-E
• Cam for:
Figure 44 Support Spring - Installed
- Loose cam.
- Surface finish.
7A-14B-22 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR
[y ] inspect
El Install or Connect
Figure 45
1. Reaction sun gear retainer ring (671) onto the
reaction sun gear, if previously removed.
2. Reaction sun gear (673) into the reaction carrier. 8 CAST, TRANSMISSION
• Index the teeth with the pinion gears. 669 WASHER, THRUST (REACTION SHAFT/SHELL)
670 SHELL, REACTION SUN
3. Thrust washer (674) onto the lo and reverse 671 RING, REACTION SUN GEAR RETAINER
support inner race. 673 GEAR, REACTION SUN
674 WASHER, THRUST (RACE/REACTION SHELL)
• Index the four locating ears into the inner
675 RACE, LO AND REVERSE ROLLER CLUTCH
race. 676 RING, LO AND REVERSE SUPPORT TO CASE RETAINER
4. Reaction sun gear shell (670) onto the reaction
sun gear. RH0142-4L60-E
5. Bronze thrust washer (669) onto the reaction Figure 45 Reaction Sun Gear and Shell In s ta lla tio n
sun gear shell.
• Index tangs into the shell.
|y | Inspect
Figures 46 and 47
Input Internal Gear and Reaction Shaft • Reaction carrier shaft (666) for:
Figures 46 and 47 - Scored, dam aged, or worn bushings (see
Bushing Replacem ent).
|<~»| Remove or Disconnect - Cracked shaft.
Figure 46 - Dam aged spline or gear teeth.
1. Retainer ring (668) from input internal gear - U n d e r c u t a ro u n d th e s h a ft fro m
(664). interference with the sun gear.
2. R eaction carrier shaft (666) from the input
internal gear.
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-23
J 21427-01
699
687
Figure 46 Input Internal Gear and Reaction Shaft Input Internal Gear and Output Shaft
F ig u re s 4 8 a n d 4 9
Transmission Output Speed Sensor Rotor
Tool Required:
F ig u re 4 7
J 29837 Output Shaft Support Fixture
Tools Required:
J 21427-01 S p e e d o m e te r G e a r P u lle r B Install or Connect
A dapter
1. Reaction shaft (666) into the input internal gear
J 8433 Speedom eter G ear Puller (664).
J 36352-6 “C ” W asher 2. Retainer ring (668) into the input internal gear.
J 36352-4 Rotor Installer 3. Input internal gear and shaft assem bly into the
M echanical press sun gear shell.
• Index the shaft spline into the reaction
If Inspect carrier.
F ig u re 4 7
4. Thrust bearing (663) onto the reaction carrier
shaft.
• Speed sensor rotor on output shaft for tooth • O uter race goes toward the reaction carrier
damage. shaft.
[T"| Important 5. Output shaft (687) into the transmission.
• Index the splines with the m ating parts.
• If rotor is dam aged, replace it. Do not reuse a
6. J 29837 onto the case.
rotor that has been removed.
• Position upw ards as far as possible to
P »| Remove or Disconnect support the output shaft.
F ig u re 4 7
[jjfr] Inspect
Figure 50
1. Input carrier assem bly (662) onto the output
shaft.
2. Retainer ring (661) into the output shaft ring
groove.
• Use care not to overexpand the ring during
installation.
• Do not reuse the old retainer ring if it has
been overexpanded.
3. Rem ove J 29837.
4. Input sun gear (658) into the input carrier.
• Rotate the sun gear teeth into the pinion
gear teeth.
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-25
8 CASE, TRANSMISSION
658 GEAR, INPUT SUN
661 RET., OUTPUT SHAFT TO INPUT CARRIER
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
RH0146-4L60-E
3. Overrun clutch spring assem bly (634). • Check valve retainer and ball assem bly (617)
4. Overrun clutch piston (632). for:
• Inner and outer lip seals (631). - Dam age.
5. Forw ard clutch piston assem bly (630). - The ball m ust m ove freely in the retainer.
• Inner and outer lip seals (629). - The retainer m ust be tight in the turbine
6. Forward clutch housing (628). shaft.
7. The 3-4 clutch spring assem bly (626). • Feed passages for:
8. The 3-4 clutch apply ring (625) and piston (623). - Obstructions - blow air through passages.
• Inner and outer lip seals (624) from piston.
9. Forward clutch to input housing O-ring seal Check Valve Retainer and Ball Assembly -
(622). Replacement Procedures
10. Four turbine shaft oil seal rings (619). F ig u re s 5 3 th r o u g h 64
Tools Required:
6.3 m m (#4) Screw extractor
9.5 m m (3/8 inch) diam eter m etal rod
6.35 m m (1/4 inch) diam eter rod or drift
ham m er
J 23456 Clutch Spring Com pressor Press
J 23327-1 Clutch Spring Com pressor
J 25018-A Clutch Spring Com pressor
Adaptor
J 29882 O verrun Clutch Inner Seal
ASSEMBLY, INPUT RH0148-4L60-E
Protector
Figure 52 Overrun Clutch Retainer Ring - Removal J 29883 Forw ard Clutch Inner Seal
Protector
[y | Inspect
|<~»| Remove or Disconnect
Figures 54 and 55
F ig u re 5 5
• Input housing for porosity or dam age
• Input housing and shaft assem bly (621) for: 1. Straighten the tangs o f the retainer and rem ove
the ball.
- Spline w ear or damage.
2. Check valve retainer.
- Three turbine shaft checkballs.
• Use 6.3 mm (#4) Screw extractor.
A. The balls m ust not be loose or leaking.
B. The open hole is the lube oil passage E Install or Connect
which feeds the output shaft.
F ig u re 5 5
• Presence of orificed cup plug (698).
• Cracks at lube holes. • New check valve retainer and ball assem bly
(617).
• Four turbine shaft oil seal ring grooves for
dam age or burrs. A. Use the 9.5 m m (3/8 inch) m etal rod.
- Seals m ust fit freely into the ring grooves. B. Seat the retainer 3.0 mm (1/8 inch) below
top surface o f the turbine shaft.
C. Be certain the ball is loose.
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-27
ILL. ILL.
IMO. DESCRIPTION NO. DESCRIPTION
600 SPRING ASM., 3-4 CLUTCH BOOST (5) 646 PLATE, FORWARD CLUTCH (APPLY)
615 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE 648 PLATE, FORWARD CLUTCH (WAVED)
WASHER 649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL)
616 WASHER, THRUST (SELECTIVE) 649B PLATE, FORWARD CLUTCH (FIBER)
617 RETAINER AND BALL ASM., CHECK VALVE 650 PLATE, FORWARD CLUTCH BACKING (SEL.)
620 RETAINER AND CHECKBALL ASSEMBLY 651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
621 HOUSING AND SHAFT ASSEMBLY, INPUT 653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
623 PISTON, 3RD AND 4TH CLUTCH 654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER)
625 RING, 3RD AND 4TH CLUTCH (APPLY) 654B PLATE, 3RD AND 4TH CLUTCH (STEEL)
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.)
627 RETAINER AND BALL ASSEMBLY, FORWARD CLUTCH 656 RING, 3RD AND 4TH CLUTCH BACKING PLATE
HOUSING RETAINER
628 HOUSING, FORWARD CLUTCH 698 PLUG, ORIFICED CUP
630 PISTON, FORWARD CLUTCH
632 PISTON, OVERRUN CLUTCH
633 BALL, OVERRUN CLUTCH
634 SPRING ASSEMBLY, OVERRUN CLUTCH
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT
645A PLATE ASSEMBLY, OVERRUN CLUTCH (STEEL)
645B PLATE, OVERRUN CLUTCH (FIBER)
A FORWARD CLUTCH SPRAG ASSEMBLY
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
644 RACE, FORWARD CLUTCH (OUTER)
SH 0149-4L60-E
|p | Inspect
F ig u re s 5 4 a n d 5 6
|~9~] Important
A LUBE PASSAGE
615 BEARING ASSEMBLY, STATOR SHAFT / SELECTIVE
WASHER
616 WASHER, THRUST (SELECTIVE) USED WITH USED WITH
620 RETAINER AND CHECKBALL ASSEMBLY 298mm CONVERTER 245mm CONVERTER
621 HOUSING AND SHAFT ASSEMBLY, INPUT
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT
A SHAFT TURBINE
687 SHAFT, OUTPUT
618 SEAL, O-RING (TURBINE SHAFT / SELECTIVE WASHER)
698 PLUG, ORIFICED CUP
621 HOUSING AND SHAFT ASSEMBLY, INPUT RH0152-4L60-E
R H0150-4L60-E
E Remove or Disconnect
F ig u re 5 7
REMOVE b
A #4 EASY OFF
B TURBINE SHAFT
C 9.5mm (3/8") METAL ROD
617 RETAINER AND BALL ASM., CHECK VALVE
RH0151-4L60-E
\jy \ Inspect
F ig u re s 5 9 a n d 6 0
J 29883 631
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
623 PISTON, 3RD AND 4TH CLUTCH 625 RING, 3RD AND 4TH CLUTCH (APPLY)
625 RING, 3RD AND 4TH CLUTCH (APPLY) 626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 628 HOUSING, FORWARD CLUTCH
628 HOUSING, FORWARD CLUTCH 630 PISTON, FORWARD CLUTCH
629 SEAL, FORWARD CLUTCH (INNER AND OUTER) 631 SEAL, OVERRUN CLUTCH (INNER AND OUTER)
630 PISTON, FORWARD CLUTCH 632 PISTON, OVERRUN CLUTCH
SH0155-4L60-E SH 0156-4L60-E
Figure 59 Forward Clutch and 3-4 Apply Ring - Figure 60 Overrun Piston - Installed
Installed
2. Inner and outer seals (629) on forw ard clutch 7. Apply ring and forw ard clutch assem bly into
piston. the input housing as shown.
• Seal lips m ust face away from the piston A. H old the assem bly by the apply ring legs
tangs as shown. during installation.
• L u b ric a te w ith T ran sjel™ J 36850 or B. Do not let the forward clutch piston separate
equivalent. from the housing.
3. Forw ard clutch piston (630) into the forw ard C. Firm ly seat the assembly.
clutch housing. 8. J 29882 on the input housing as shown.
• Use care not to dam age the outer lip seal. 9. Overrun clutch piston (632).
4. The 3-4 clutch spring assem bly (626) onto the • Hub facing upward as shown.
3-4 clutch apply ring.
• If all parts are properly seated to this point,
5. Forw ard clutch assem bly onto the 3-4 clutch th e o v e rru n p is to n h u b w ill be
spring assembly. approxim ately 4.7 mm (3/16 in.) below the
• The forw ard clutch piston apply legs m ust top o f the snap ring groove in the input
be indexed with the 3-4 clutch apply ring housing hub.
legs.
6. J 29883 on the input housing as shown.
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-31
Assemble Inspect
F ig u re s 6 1 a n d 6 2 Overrun clutch plates (645) for:
1. O verrun clutch spring assem bly (634) onto the - C o m p o s itio n p la te d a m a g e d ta n g s ,
overrun clutch piston. delam ination, or excessive wear.
• Locate the springs on the piston tabs. - Steel plate dam aged tangs, wear, or heat
damage.
2. J 23456 and J 23327-1 with J 25018-A onto the
overrun spring assembly. Input sun gear bearing assem bly (637) for:
• Com press springs (Do not over-com press). - Wear.
- Flatness.
3. R etainer snap ring (635) into the snap ring
groove. - Dam aged.
4. Input housing to output shaft lip seal (636). Assemble
F ig u re s 6 3 a n d 6 4
,J 23327-1
J 23456 1. O verrun clutch plates (645) into the input
housing.
• Overrun clutch plates are the sm allest of
the three sets of plates in the input
housing.
• Index the plates as shown starting with a
steel plate and alternate with com position.
2. Thrust bearing assem bly (637) onto the input
clutch hub.
621 HOUSING AND SHAFT • The inside race m ust face the input housing
ASSEMBLY, INPUT RH0148-4L60-E hub.
• R e ta in w ith T ra n s je l™ J 3 6 8 5 0 o r
equivalent.
3. Align the tangs on the two composition overrun
clutch plates.
OVERRUN CLUTCH
THICK THICK
NO. NO.
NESS NESS
|-»fr-| Assemble
|y | Inspect
Figures 69 and 70
• Forw ard (649) and 3-4 clutch plates (654) for:
- C o m p o s itio n p la te d a m a g e d ta n g s ,
A R c p c c c p n FAPF
delam ination, or wear.
B NOTCHES POINT UPWARD AS SHOWN - Steel plate dam aged tangs, wear, or heat
C LIPPED EDGE damage.
642 FORWARD SPRAG ASSEMBLY
644 RACE, FORWARD CLUTCH (OUTER) • Forw ard (650) and 3-4 clutch backing plates
(655) for:
Figure 66 Sprag Assembly Procedure - Flatness.
- Surface finish damage.
- Burrs or nicks.
• Forw ard clutch apply plate (646) and spacer
plate (647) for:
- Flatness.
- Surface finish damage.
- Burrs or nicks.
|^ | Assemble
F ig u re s 6 9 th r o u g h 7 2
[q I Measure
RH0166-4L60-E
RH0165-4L60-E-R1
Figure 71 Forward Clutch Plate Chart
Figure 70 Input Housing with Forward and 3-4 Clutch
Plates
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-35
^ 651
650" \
RH0168-4L60-E-R1
DIM. I.D.
5.88mm - 5.68mm
A
(.231"-.224”)
4.10mm - 3.90mm
C
(.161"-.154")
Adjust
600 SPRING ASM., 3-4 CLUTCH BOOST (5) 642 FORWARD SPRAG ASSEMBLY
619 RING, OIL SEAL (SOLID) 643 RETAINER RINGS, SPRAG ASSEMBLY
620 RETAINER AND CHECKBALL ASSEMBLY 644 RACE, FORWARD CLUTCH (OUTER)
621 HOUSING AND SHAFT ASSEMBLY, INPUT 645A PLATE ASSEMBLY, OVERRUN CLUTCH (STEEL)
622 SEAL, O-RING INPUT TO FORWARD HSG. 645B PLATE, OVERRUN CLUTCH (FIBER)
623 PISTON, 3RD AND 4TH CLUTCH 646 PLATE, FORWARD CLUTCH (APPLY)
625 RING, 3RD AND 4TH CLUTCH (APPLY) 648 PLATE, FORWARD CLUTCH (WAVED)
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL)
628 HOUSING, FORWARD CLUTCH 649B PLATE, FORWARD CLUTCH (FIBER)
629 SEAL, FORWARD CLUTCH (INNER AND OUTER) 650 PLATE, FORWARD CLUTCH BACKING (SEL.)
630 PISTON, FORWARD CLUTCH 651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
631 SEAL, OVERRUN CLUTCH (INNER AND OUTER) 653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
632 PISTON, OVERRUN CLUTCH 654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER)
634 SPRING ASSEMBLY, OVERRUN CLUTCH 654B PLATE, 3RD AND 4TH CLUTCH (STEEL)
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER 655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.)
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT 656 RING, 3RD AND 4TH CLUTCH BACKING PLATE
637 BEARING ASSEMBLY, INPUT SUN GEAR RETAINER
638 SNAP RING, OVERRUN CL. HUB RETAINING
639 HUB, OVERRUN CLUTCH
641 RETAINER AND RACE ASSEMBLY, SPRAG S H 0172-4L60-
23327-1
614
613
J 25018-A
612B UNDER
J 23327-1
Figures 78 and 80
• Backing plate (613) for:
- Dam age.
- Distortion or flatness.
- Burrs or surface finish damage.
• Clutch Plates (612) for:
- C o m p o s itio n p la te ta n g dam age,
delam ination, or wear.
- Steel plate tang dam age, wear, or heat
damage.
• Spring assem bly (609) for distortion or damage.
• Piston (607) for:
- Dam age or porosity.
- Ring groove damage.
• H ousing and drum assem bly (605) for:
- Dam aged or worn bushings (603 and 606).
- Surface on the hub and outer housing.
- Leak at the weld.
ILL.
NO. DESCRIPTION
605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT
CLUTCH
607 PISTON ASM., REVERSE INPUT CLUTCH
608 SEALS, REVERSE INPUT CLUTCH
(INNER AND OUTER)
609 SPRING ASM., REVERSE INPUT CLUTCH
610 RING, REVERSE INPUT CLUTCH SPRING RETAINER
611 PLATE, REVERSE INPUT CLUTCH (BELLEVILLE)
612A PLATE ASM., REVERSE INPUT CLUTCH (STEEL)
612B PLATE, REVERSE INPUT CLUTCH (FIBER)
613 PLATE, REVERSE INPUT CLUTCH BACKING (SELECTIVE)
614 RING, REVERSE INPUT CL. RETAINING A CHECK FOR DISHING AT THIS POINT
605 HOUSING AND DRUM ASSEMBLY,
REVERSE INPUT CLUTCH R H 0175-4L60-E
RH0173-4L60-E
Figure 80 Check Reverse Input Housing For Dishing
Figure 78 Reverse Input Clutch Assembly
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-39
NO. THICKNESS
2.311mm (.091")
BELLEVILLE PLATE 1
2.210mm (.087")
R H0177-4L60-E
7.249mm - 7.409mm 9
(.285" - .292")
6.678mm - 6.519mm q
o
(.263" - .257")
5.947mm - 5.787mm
(.234" - .228")
RH0178-4L60-E
Figure 84 Reverse Input Clutch Figure 85 Thrust Bearing and Selective Washer
Location
|nfc| Assemble
F ig u re s 8 5 a n d 8 6
Assemble
F ig u re 8 7
B Remove or Disconnect
1. Thrust w asher (601).
2. Pump cover to case gasket (6).
3. Pump to case oil seal (5).
4. Pump cover bolts (233).
5. Pum p cover (215) from pum p body (200).
|^ | Assemble
F ig u re s 8 7 a n d 8 8
2. From the pum p pocket: • Pum p cover (215) and pum p body (200) for:
• Pum p guide rings (210) - Worn or dam aged bushings (see Bushing
• Pum p vanes (213) Replacem ent Procedure).
• Pum p rotor (212) - Foreign m aterial or debris.
• Pump guide (211) - Porosity.
• Slide (209) - Scored or irregular m ating faces.
• Slide seal (201) - Cross channel leaks.
• Seal support (208) - Ring groove damage.
• Pivot slide pin (205) and spring (204) • R otor (212) and slide (203) for cracks.
• Slide seal ring (201) and slide back up seal • Oil seal assem bly for dam age or wear.
(202) f*y| Clean
3. Retainer (94), oil seal assem bly (2).
• Pry out with a screwdriver. • W ash and air dry all parts.
|"f"| Important
Oil Pump Cover • Do not wipe dry with a cloth.
F ig u re s 9 0 , 9 1 a n d 9 4
Tool Required:
One inch m icrom eter OIL PUMP ROTOR SELECTION CHART
THICKNESS (mm) THICKNESS (in.)
pfrl Disassemble
17.948 - 17.961 0.7066-0.7071
F ig u re s 9 1 a n d 9 4 17.961 - 17.974 0.7071 - 0.7076
17.974- 17.987 0.7076 - 0.7081
1. Converter clutch apply valve train.
17.987 - 18.000 0.7081 - 0.7086
A. Com press converter clutch stop valve (223)
18.000- 18.013 0.7086 - 0.7091
with a screwdriver.
B. Rem ove retaining ring (222). OIL PUMP SLIDE SELECTION CHART
C. Slowly release the spring tension.
THICKNESS (mm) THICKNESS (in.)
D. Stop valve (223), converter clutch apply
valve (224) and two converter clutch valve 17.948- 17.961 0.7066 - 0.7071
springs. 17.961 - 17.974 0.7071 - 0.7076
17.974- 17.987 0.7076 - 0.7081
2. Pressure relief ball (228). 17.987 - 18.000 0.7081 - 0.7086
• Ball is under strong spring pressure. 18.000-18.013 0.7086 - 0.7091
• Cover the ball with a cloth when rem oved.
3. Pressure regulator assem bly (216-221).
• Follow the same procedure used to rem ove
the converter clutch valve.
[F I Inspect
F ig u re 9 1
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
212 ROTOR, OIL PUMP
213 VANE, PUMP
214 SHAFT, STATOR
215 COVER, PUMP
216 VALVE, PRESSURE REGULATOR
217 SPRING, PRESSURE REGULATOR VALVE
218 SPRING, PRESSURE REGULATOR ISOLATOR
219 VALVE, REVERSE BOOST
220 SLEEVE, REVERSE BOOST VALVE
221 RING, OIL PUMP REVERSE BOOST VALVE
RETAINING
222 RING, OIL PUMP CONVERTER CLUTCH VALVE
RETAINING
223 VALVE, STOP
224 VALVE, CONVERTER CLUTCH
225 SPRING, CONVERTER CLUTCH VALVE (INNER)
226 SPRING, CONVERTER CLUTCH VALVE (OUTER)
227 RIVET, PRESSURE RELIEF BOLT
228 BALL, PRESSURE RELIEF
229 SPRING PRESSURE RELIEF
230 RING, OIL SEAL (STATOR SHAFT)
231 SEAL, OIL PUMP COVER SCREEN
232 SCREEN, OIL PUMP COVER
233 BOLT, M8 X 1.25 X 40 (COVER TO BODY)
234 BUSHING, STATOR SHAFT (FRONT)
235 PLUG, OIL PUMP COVER (FWD CLUTCH FEED)
236 PLUG, OIL PUMP COVER
237 RETAINER AND BALL ASSEMBLY, CHECK VALVE
238 ORIFICE, CONVERTER CLUTCH SIGNAL
(CUP PLUG)
240 PLUG, CUP ORIFICE
241 BUSHING, STATOR SHAFT (REAR)
242 BUSHING, PUMP BODY
243 SEAL ASSEMBLY, OIL
244 RETAINER, FRONT HELIX
SH 0185-4L60-E
m Important
• M easurem ent o f rotor/slide m ust be m ade on
u n d a m a g e d s u rfa c e s . S e le c t s im ila r size
rep la ce m e n ts. L ig h tly hone b o th sid es o f
replacem ent rotor or slide to rem ove any nicks
or burrs.
Assemble
Assemble
Figures 91, 95,96 and 97
1. Oil pum p cover (215) onto oil pum p body.
• Stator shaft through a bench hole
2. Pum p cover bolts (233).
• Leave finger tight.
3. Align pum p cover and pum p body with J 21368.
• Place a screwdriver through a bolt hole and
into a hole in the bench.
Tighten
• A ttaching bolts to 24 N*m (18 lb. ft.).
• R e ta in w ith T ra n s je l™ J 3 6 8 5 0 o r
equivalent.
4. Install two oil seal rings (233) using J38735-3
and J 39855-1.
j9 Adjust
RH0188-4L60-E
| 9 | Important
J 21368
RH0189-4L60-E
RH0192-4L60-E
CORRECTLY
A 298mm TURBINE SHAFT
B 245mm TURBINE SHAFT
RH0114-4L60-E
RH0180-4L60-E
Figure 100 J 25022-A Installed Figure 102 Selective Washer and Thrust Bearing
Properly Installed
7A-14B-48 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR
|^ | Assemble [y | Inspect
HD, SA NO P A IN T V IO LET
HB W H ITE VIO LE T
BB, BC OR AN G E V IO LET
1994 M O D E LS COLOR
C M , CU, KP RED
BB, BC DK GREEN
RH0194-4L60-E-R1
46 SPRING, 3-4 ACCUMULATOR Figure 106 1-2 and 3-4 Accumulator Spring Chart
47 GASKET, SPACER PLATE TO CASE
48 PLATE, VALVE BODY SPACER
52 GASKET, SPACER PLATE TO VALVE BODY
53 PLATE, SPACER PLATE SUPPORT B Install or Connect
54 SPRING, 1-2 ACCUMULATOR 1. The wiring harness pass-thru connector into the
54A SPRING, 1-2 ACCUMULATOR (INNER)
57 COVER AND PIN ASSEMBLY, 1-2 ACCUMULATOR case.
58 BOLT, ACCUMULATOR COVER 2 . The 3-4 accum ulator pin (43) into the case.
59 BOLT, ACCUMULATOR COVER
77 BOLT, SPACER PLATE SUPPORT RH0233-4L60-E-R1 3. The 3-4 accum ulator piston seal (45) onto the
3-4 accum ulator piston.
Figure 105 Accumulator Assembly, Spacer Plate The 3-4 accum ulator piston (44) onto the pin.
and Gaskets
• The end with three legs m ust face the valve
body.
Valve Body and Associated Parts
5. The 3-4 accum ulator piston spring (46).
Figures 105 and 107
Install or Connect
Tool Required:
1. Torque converter clutch oil screen (92).
J 25025-5 Guide Pins
2. Checkball (91) into case as shown.
NOTICE: The use o f a honing stone, fine • R e ta in w ith T ra n s je l™ J 3 6 8 5 0 o r
sandpaper or crocus cloth is not recom m ended equivalent.
for servicing stuck valves. All valve lands have 3. J 25025-5 into the case.
sharply m achined corners that are necessary for 4. Screens onto spacer plate as shown.
“cleaning” the bore. If these corners are rounded, Spacer plate to case gasket (47) and spacer plate
5.
foreign m aterial could wedge betw een the valve to valve body gasket (52) onto the spacer plate
and bore causing the valve to stick.
(48).
If it is found necessary to clean a valve, “m icro • G asket (47) identified by a “C” .
fine” lapping com pound 900 grit or finer should G asket (52) identified by a “V ”.
be used.
• R e ta in w ith T ra n s je l™ J 3 6 8 5 0 or
Too m uch “ lap p in g ” o f a v alv e w ill cau se equivalent.
excessive clearances and increase the chance o f a
valve not operating.
7A-14B-50 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR
6. Spacer plate and gaskets onto the case. 12. Bore plug retainer (395), bore plug (381) and
3-2 control valve train (391 - 393).
ffl Important 13. 3-2 dow nshift bore plug retainer (395), bore
• Be careful not to dam age screens when plug (381) and valve train (389 - 390).
installing the spacer plate and gaskets. 14. Reverse abuse bore plug retainer pin (360), bore
plug (359) and valve train (387 - 388).
7. Spacer plate support (53) and bolts (77). 15. 3-4 shift valve bore plug retainer (395), bore
plug (381) and valve train (385 - 386).
fix l Tighten
16. 3-4 relay bore plug retainer (395), bore plug
• Bolts to 11 N #m (8 lb. ft.) (381) and valve train (382 - 384).
17. Torque converter clutch signal valve bore plug
Control Valve Body retainer (395), bore plug (381) and valve (380).
• Control valve assem bly thoroughly in clean • All valves, springs, bushings and control valve
solvent. body in clean solvent.
A. M ove the valves w ith a pick or sm all • Dry using com pressed air
screw driver to dislodge any dirt or debris
that may have accum ulated. [y | Inspect
B. A ir dry • All valves and bushings for:
- Porosity
B Remove or Disconnect - Scoring
- Nicks
PH Important
- Scratches
• Some valves are under pressure - cover the • Springs for dam aged or distorted coils.
bores while rem oving roll pins and retainer
• Valve body casting for:
clips.
- Porosity
• Valves, springs and bushings m ust be laid
out on a clean surface in the exact sequence - Cracks
they are rem oved. - Interconnected oil passages
1. Pressure control solenoid retainer bolt (364) - Dam aged m achined surfaces
retainer (378) and solenoid.
Assemble
2. Bore plug retainer clip (395), bore plug (376)
and valve train (374 and 375). • Control valve assem bly (350) exactly as shown.
3. 2-3 shift solenoid retainer (379), solenoid (367) - Notice the position o f the valve lands and
and valve train (368 and 369). bushing passages.
4. 1-2 shift solenoid retainer (379), solenoid (367) - Position the pressure control solenoid so
and valve train (365 and 366). the connector tabs face outward.
5. Accum ulator valve train retainer pin (360), bore NOTICE: TCC PW M solenoid (396) cannot be
plug (373) and valve train (370 and 371). installed until TCC solenoid has been installed
6. Forw ard accum ulator cover bolts (364) and and torqued to proper specifications.
cover (363).
7. Forward accum ulator spring (356), piston (354) p *| Install or Connect
and pin (355). 1. Checkballs into the valve body assem bly (350).
8. Lo overrun valve spring (362) and valve (361). • R e ta in w ith T ra n s je l™ J 3 6 8 5 0 or
9. Retainer pin (360), bore plug (359) and forward equivalent.
abuse valve train (357 and 358). 2. Valve body assem bly (350).
10. M anual valve (340). • Connect the m anual valve link (89) to the
11. 3-2 control solenoid retainer clip (379) and inside detent lever (88).
solenoid (394).
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-51
Install or Connect
• W irin g h a rn e ss c o n n e c tio n s to e le c tric a l
38 PLUG, TRANSMISSION CASE (ACCUM. BLEED)
com ponents. 40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM.
91 NO. 1 CHECKBALL
To correctly hook up the wires, see the wiring 92 SCREEN, TCC
diagram in the HYDRA-M ATIC 4L60-E Diagnosis
RH0113-4L60-E
Section.
The pressure control solenoid (377) has two Figure 107 Case Checkballs and Oil Screens - Location
different colored connectors. The black connector
should be installed on the tab farthest from the valve
body. 49
Install or Connect
1. Parking bracket (86).
[^ | Tighten
• Bolts to 31 N -m (23 lb. ft.)
2. The 1-2 accum ulator piston seal (55) onto the
1-2 accum ulator piston (56).
3. The 1-2 accum ulator piston (56) into the 1-2
accum ulator cover and pin assem bly (57).
• The three legs on the piston m ust face
toward the case when installed.
4. T he 1-2 ac cu m u la to r spring (54) and 1-2
accum ulator inner spring (54A) onto the piston
(56).
5. The 1-2 accum ulator cover and pin assem bly
(57) onto the case.
P&l Tighten
49 SHIFT SOLENOIDS SCREEN
• Torque to 11 N*m (8 lb. ft.) 50 PRESSURE CONTROL SOLENOID SCREEN
_________ RH0234-4L60-E
SH0196-4L60-E
#3 #2
2 3RD ACCUMULATOR
3 REVERSE INPUT
4 3-4 CLUTCH EXHAUST
5 OVERRUN CLUTCH FEED
6 OVERRUN CLUTCH CONTROL
8 1-2 UPSHIFT
12 FORWARD CLUTCH ACCUM. R H0112-4L60-E
A M6 X 1.0 X 65.0
B M6 X 1.0 X 54.4
O O P C M6 X 1.0 X 47.5
D M6 X 1.0 X 18.0
E M6 X 1.0 X 35.0
F M8 X 1.25 X 20.0
G M6 X 1.0 X 12.0
S H 0T97-4L60-E
Figure 114 Outside Electrical Connector Figure 115 Case, Pan and Filter Assembly
MM INCH
Q ] Important
Figure 117 2nd Apply Piston and Housing
• Check servo bore in the case for any w ear which Measurement
may cut the servo seals.
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-57
|jjtj 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. Com press the retainer past the snap ring
groove in the 2nd apply piston.
B. Install the retainer ring (14).
4. The 2nd apply piston (17) onto the apply pin
(13)
• Retainer goes tow ard the shoulder o f the
pin.
5. Servo apply pin spring (22) on the pin.
6. Servo apply pin w asher (23) and retaining clip
(24).
7. Inner (19) and outer (18) seals on the 2nd apply
piston (17).
• R e ta in w ith T ra n s je l™ J 3 6 8 5 0 o r
equivalent.
8. O-ring seal (21) on servo piston housing.
9. Servo piston inner housing (20) on the 2nd apply
piston.
10. Seal ring (26) onto the 4th apply piston.
11. The 4th apply piston (25) onto the apply pin.
12. Return spring (12) on the pin.
13. Servo piston assem bly into the servo bore.
14. O-ring seal (21) on the servo cover.
• L ubricate the seal w ith T ransjel™
J 36850 or equivalent.
15. Servo cover (28) into the servo bore.
ILL. 16. Install J 29714.
IMO. DESCRIPTION
A. Com press the servo cover.
12 SPRING, SERVO RETURN
13 PIN, 2ND APPLY PISTON B. Install the retainer ring (29).
14 RING, RETAINER (2ND APPLY PISTON)
15 RETAINER, SERVO CUSHION SPRING
16 SPRING, SERVO CUSHION
17 PISTON, 2ND APPLY
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER)
19 RING, OIL SEAL (2ND APPLY PISTON - INNER)
20 HOUSING, SERVO PISTON (INNER)
21 SEAL, O-RING
22 SPRING, SERVO APPLY PIN
23 WASHER, SERVO APPLY PIN
24 RING, RETAINER (APPLY PIN)
25 PISTON, 4TH APPLY
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER) J 22269-01
27 SEAL, O-RING (2-4 SERVO COVER)
28 COVER, 2-4 SERVO
29 RING, SERVO COVER RETAINING 14 RING, RETAINER (2ND APPLY PISTON)
17 SECOND APPLY PISTON RH0103-4L60-E
R H0104-4L60-E
Figure 119 2nd Servo Piston - Assembly
[jF^] Inspect
GJ Important
• F lu s h in g th e to rq u e c o n v e rte r is not
recom m ended.
E Install or Connect
1. Torque converter.
2. J 21366 converter holding strap.
3. Rem ove transm ission from holding fixture.
RH0204-4L60-E
ILL. ILL.
NO. DESCRIPTION NO. DESCRIPTION
1 TORQUE CONVERTER ASSEMBLY 48 PLATE, VALVE BODY SPACER
2 BOLT, PUMP TO CASE 49 SCREEN, SHIFT SOLENOIDS
3 O-RING, PUMP TO CASE BOLT 50 SCREEN, PRESSURE CONTROL SOLENOID
4 PUMP ASSEMBLY, OIL 52 GASKET, SPACER PLATE TO VALVE BODY
5 SEAL, OIL (PUMP TO CASE) 53 PLATE, SPACER PLATE SUPPORT
6 GASKET, PUMP COVER TO CASE 54 SPRING, 1-2 ACCUMULATOR
7 BUSHING, CASE 54A SPRING, 1-2 ACCUMULATOR (INNER)
8 CASE, TRANSMISSION 55 RING, OIL SEAL (1-2 ACCUMULATOR)
9 VENT ASSEMBLY, TRANSMISSION 56 PISTON, 1-2 ACCUMULATOR
10 CONNECTOR, OIL COOLER PIPE 57 COVER AND PIN ASSEMBLY, 1-2 ACCUMULATOR
11 PLUG, CASE SERVO 58 BOLT, ACCUMULATOR COVER
12 SPRING, SERVO RETURN 59 BOLT, ACCUMULATOR COVER
13 PIN, 2ND APPLY PISTON 60 VALVE ASSEMBLY, CONTROL BODY
14 RING, RETAINER (2ND APPLY PISTON) 61 CHECKBALL
15 RETAINER, SERVO CUSHION SPRING 62 BOLT, VALVE BODY
16 SPRING, SERVO CUSHION 63 SPRING ASSEMBLY, MANUAL DETENT
17 PISTON, 2ND APPLY 64 BOLT, MANUAL DETENT SPRING
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER) 65 SEAL, WIRING HARNESS PASS-THRU CONNECTOR
19 RING, OIL SEAL (2ND APPLY PISTON - INNER) O-RING
20 HOUSING, SERVO PISTON (INNER) 66 SOLENOID ASSEMBLY, WIRING HARNESS
21 SEAL, O-RING 67 SEAL, O-RING (SOLENOID)
22 SPRING, SERVO APPLY PIN 68 BOLT, HEX WASHER HEAD (SOLENOID)
23 WASHER, SERVO APPLY PIN 69 SWITCH ASSEMBLY, TRANSMISSION PRESSURE
24 RING, RETAINER (APPLY PIN) 70 BOLT, PRESSURE SWITCH ASSEMBLY
25 PISTON, 4TH APPLY 71 SEAL, FILTER
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER) 72 FILTER ASSEMBLY, TRANSMISSION OIL
27 SEAL, O-RING (2-4 SERVO COVER) 73 GASKET, TRANSMISSION OIL PAN
28 COVER, 2-4 SERVO 74 MAGNET, CHIP COLLECTOR
29 RING, SERVO COVER RETAINING 75 PAN, TRANSMISSION OIL
30 SEAL, CASE EXTENSION TO CASE 76 SCREW, TRANSMISSION OIL PAN
31 EXTENSION, CASE 77 BOLT, SPACER PLATE SUPPORT
32 BOLT, CASE EXTENSION TO CASE 78 PLUG, STEEL CUP
33 BUSHING, CASE EXTENSION 79 SHAFT, PARKING BRAKE PAWL
34 SEAL ASSEMBLY, CASE EXTENSION OIL 80 SPRING, PARKING PAWL RETURN
35 BOLT, SPEED SENSOR RETAINING 81 PAWL, PARKING BRAKE
36 SPEED SENSOR, INTERNAL TRANSMISSION 82 SEAL, MANUAL SHAFT
37 SEAL, O-RING (ITSS TO CASE EXTENSION) 83 RETAINER, MANUAL SHAFT
38 PLUG, TRANSMISSION CASE (ACCUM. BLEED) 84 SHAFT, MANUAL
39 PLUG, PRESSURE 85 ACTUATOR ASSEMBLY, PARKING LOCK
40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM. 86 BRACKET, PARKING LOCK
41 PIN, BAND ANCHOR 87 BOLT, PARKING LOCK BRACKET
42 RETAINER AND BALL ASM. (DOUBLE ORIFICE) 88 LEVER, INSIDE DETENT
43 PIN, ACCUMULATOR PISTON 89 LINK, MANUAL VALVE
44 PISTON, 3-4 ACCUMULATOR 90 NUT, HEX HEAD
45 RING, OIL SEAL (3-4 ACCUMULATOR PISTON) 91 NO. 10 CHECKBALL
46 SPRING, 3-4 ACCUMULATOR 92 SCREEN,TCC
47 GASKET, SPACER PLATE TO CASE 93 BRACKET, DIPSTICK STOP
R H0206-4L60-E-R2
ILL. ILL.
NO. DESCRIPTION NO. DESCRIPTION
600 SPRING ASM., 3-4 CLUTCH BOOST (5) 654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER)
601 WASHER, THRUST (PUMP TO DRUM) 654B PLATE, 3RD AND 4TH CLUTCH (STEEL)
602 BAND ASSEMBLY, 2-4 655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.)
603 BUSHING, REVERSE INPUT CL. (FRONT) 656 RING, 3RD AND 4TH CLUTCH BACKING PLATE
605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT RETAINER
CLUTCH 657 BUSHING, INPUT SUN GEAR (FRONT)
606 BUSHING, REVERSE INPUT CLUTCH (REAR) 658 GEAR, INPUT SUN
607 PISTON ASM., REVERSE INPUT CLUTCH 659 BUSHING, INPUT SUN GEAR (REAR)
608 SEALS, REVERSE INPUT CLUTCH 661 RET., OUTPUT SHAFT TO INPUT CARRIER
(INNER AND OUTER) 662 CARRIER ASSEMBLY, INPUT (COMPLETE)
609 SPRING ASM., REVERSE INPUT CLUTCH 663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
610 RING, REVERSE INPUT CLUTCH SPRING RETAINER REACTION SHAFT)
611 PLATE, REVERSE INPUT CLUTCH (BELLEVILLE) 664 GEAR, INPUT INTERNAL
612A PLATE ASM., REVERSE INPUT CLUTCH (STEEL) 665 BUSHING, REACTION CARRIER SHAFT (FRONT)
612B PLATE, REVERSE INPUT CLUTCH (FIBER) 666 SHAFT, REACTION CARRIER
613 PLATE, REVERSE INPUT CLUTCH BACKING 667 BUSHING, REACTION CARRIER SHAFT (REAR)
(SELECTIVE) 668 RING, REACTION SHAFT/INTERNAL GEAR RETAINER
614 RING, REVERSE INPUT CL. RETAINING 669 WASHER, THRUST (REACTION SHAFT/SHELL)
615 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE 670 SHELL, REACTION SUN
WASHER 671 RING, REACTION SUN GEAR RETAINER
616 WASHER, THRUST (SELECTIVE) 672 BUSHING, REACTION SUN
617 RETAINER AND BALL ASM., CHECK VALVE 673 GEAR, REACTION SUN
618 SEAL, O-RING (TURBINE SHAFT/ SELECTIVE WASHER) 674 WASHER, THRUST (RACE/REACTION SHELL)
619 RING, OIL SEAL (SOLID) 675 RACE, LO AND REVERSE ROLLER CLUTCH
620 RETAINER AND CHECKBALL ASSEMBLY 676 RING, LO AND REVERSE SUPPORT TO CASE RETAINER
621 HOUSING AND SHAFT ASSEMBLY, INPUT 677 RING, LO AND REVERSE RETAINER (ROLLER
622 SEAL, O-RING INPUT TO FORWARD HSG. ASSEMBLY/CAM)
623 PISTON, 3RD AND 4TH CLUTCH 678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
625 RING, 3RD AND 4TH CLUTCH (APPLY) 679 SUPPORT ASM., LO AND REVERSE CLUTCH
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
627 RETAINER AND BALL ASSEMBLY, FORWARD CLUTCH SUPPORT RETAINER)
HOUSING 681 CARRIER ASSEMBLY, REACTION
628 HOUSING, FORWARD CLUTCH 682A PLATE, LO AND REVERSE CLUTCH (WAVED)
629 SEAL, FORWARD CLUTCH (INNER AND OUTER) 682 B PLATE, SPACER LO AND REVERSE CLUTCH
630 PISTON, FORWARD CLUTCH (SELECTIVE)
631 SEAL, OVERRUN CLUTCH (INNER AND OUTER) 682C PLATE ASSEMBLY, LO AND REVERSE CLUTCH (FIBER)
632 PISTON, OVERRUN CLUTCH 682 D PLATE, LO AND REVERSE CLUTCH (STEEL)
633 BALL, OVERRUN CLUTCH 683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
634 SPRING ASSEMBLY, OVERRUN CLUTCH SUPPORT)
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER 684 GEAR, INTERNAL REACTION
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT 685 SUPPORT, INTERNAL REACTION GEAR
637 BEARING ASSEMBLY, INPUT SUN GEAR 686 RING, REACTION GEAR/SUPPORT RETAINER
638 SNAP RING, OVERRUN CL. HUB RETAINING 687 SHAFT, OUTPUT
639 HUB, OVERRUN CLUTCH 690 SLEEVE, OUTPUT SHAFT
641 RETAINER AND RACE ASSEMBLY, SPRAG 691 SEAL, OUTPUT SHAFT
642 FORWARD SPRAG ASSEMBLY 692 BRG., REACTION GEAR SUPPORT TO CASE
643 RETAINER RINGS, SPRAG ASSEMBLY 693 RING, LO AND REVERSE CLUTCH RETAINER
644 RACE, FORWARD CLUTCH (OUTER) 694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
645A PLATE ASSEMBLY, OVERRUN CLUTCH (STEEL) 695 PISTON, LO AND REVERSE CLUTCH
645B PLATE, OVERRUN CLUTCH (FIBER) 696 SEAL, TRANSMISSION (LO AND REVERSE CLUTCH -
646 PLATE, FORWARD CLUTCH (APPLY) OUTER, CENTER, INNER)
648 PLATE, FORWARD CLUTCH (WAVED) 697 DEFLECTOR, OIL (HIGH OUTPUT MODELS ONLY)
649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL) 698 PLUG, ORIFICED CUP
649B PLATE, FORWARD CLUTCH (FIBER) 699 ROTOR, INTERNAL TRANSMISSION SPEED SENSOR
650 PLATE, FORWARD CLUTCH BACKING (SEL.)
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
SH0208-4L60-E
S H 0195-4L60-E
SH0196-4L60-E
3-2 CONTROL
MANUAL VALVE
SH 0209-4L60-E
REGULATOR
APPLY
BLU
PUR
ILL.
NO. 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
212 ROTOR, OIL PUMP
213 VANE, PUMP
214 SHAFT, STATOR
215 COVER, PUMP
216 VALVE, PRESSURE REGULATOR
217 SPRING, PRESSURE REGULATOR VALVE
218 SPRING, PRESSURE REGULATOR ISOLATOR
219 VALVE, REVERSE BOOST
220 SLEEVE, REVERSE BOOST VALVE
221 RING, OIL PUMP REVERSE BOOST VALVE
RETAINING
222 RING, OIL PUMP CONVERTER CLUTCH VALVE
RETAINING
223 VALVE, STOP
224 VALVE, CONVERTER CLUTCH
225 SPRING, CONVERTER CLUTCH VALVE (INNER)
226 SPRING, CONVERTER CLUTCH VALVE (OUTER)
227 RIVET, PRESSURE RELIEF BOLT
228 BALL, PRESSURE RELIEF
229 SPRING PRESSURE RELIEF
230 RING, OIL SEAL (STATOR SHAFT)
231 SEAL, OIL PUMP COVER SCREEN
232 SCREEN, OIL PUMP COVER
233 BOLT, M8 X 1.25 X 40 (COVER TO BODY)
234 BUSHING, STATOR SHAFT (FRONT)
235 PLUG, OIL PUMP COVER (FWD CLUTCH FEED)
236 PLUG, OIL PUMP COVER
237 RETAINER AND BALL ASSEMBLY, CHECK VALVE
238 ORIFICE, CONVERTER CLUTCH SIGNAL
(CUP PLUG)
239 ORIFICE, OIL COOLER (CUP PLUG)
240 PLUG, CUP ORIFICE
241 BUSHING, STATOR SHAFT (REAR)
242 BUSHING, PUMP BODY
243 SEAL ASSEMBLY, OIL
244 RETAINER, FRONT HELIX
SH 0185-4L60-E
608
3 O-RING, PUMP TO CASE BOLT 618 SEAL, O-RING (TURBINE SHAFT/ SELECTIVE
5 SEAL, OIL (PUMP TO CASE) WASHER)
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER) 619 RING, OIL SEAL (SOLID)
19 RING, OIL SEAL (2ND APPLY PISTON - INNER) 622 SEAL, O-RING INPUT TO FORWARD HSG.
21 SEAL, O-RING 629 SEAL, FORWARD CLUTCH (INNER AND OUTER)
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER) 631 SEAL, OVERRUN CLUTCH (INNER AND OUTER)
27 SEAL, O-RING (2-4 SERVO COVER) 636 SEAL, INPUT HOUSING TO OUTPUT SHAFT
30 SEAL, CASE EXTENSION TO CASE 691 SEAL, OUTPUT SHAFT
34 SEAL ASSEMBLY, CASE EXTENSION OIL 696 SEAL, TRANSMISSION (LO AND REVERSE
37 SEAL, O-RING (ITSS TO CASE EXTENSION) CLUTCH -OUTER, CENTER, INNER)
230 RING, OIL SEAL (STATOR SHAFT)
243 SEAL ASSEMBLY, OIL
608 SEALS, REVERSE INPUT CLUTCH (INNER AND
OUTER)
S H 0211-4L60-E
SH 0212-4L60-E
TORQUE SPECIFICATIONS
R H0235-4L60-E
J 21465-15
J 25019-14 J 25019-6
241 241
J 8092
J 25019-4
J 34196-12
J 7004-1
J 25019-16
SH 0213-4L60-E
J 8092
J 34196-4
J 34196-6
J 34196-5
J 23907
J 7004-1
J 34196-3
J 25019-14
J 34196-3
J 34196-1 J 34196-1
RH0214-4L60-E
J 8092 J 8092
J 23062-14
J 34196-4
J 8092
RH0215-4L60-E
SPECIAL TOOLS
SPECIAL TOOLS
SPEED SENSOR ROTER SPEEDOMETER GEAR HANDLE INNER FORWARD CLUTCH
INSTALLER INSTALLER SEAL PROTECTOR
J 34196
DIAL INDICATOR STAND & GUIDE PIN SET
_____ ____________ zm
a m ...............................' - i - m io “ 3 * « « « - — ' ---r-flM D
I J 35944
RH0236-4L60-E
J 25025-B
Figure 144 Special Tools
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-1
SECTION 7A-17B
HYDRA-MATIC 4L80-E
AUTOMATIC TRANSMISSION UNIT REPAIR
RPO MT1
NOTICE: W hen 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 num ber fastener for the application. If the correct
part num ber is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not
reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CAUTION: On vehicles equipped with Supplemental Inflatable Restraint (SIR), refer to CAUTIONS in
Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring Location view in
Section 9J before performing service on or around SIR components or wiring. Failure to follow
CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR
system repairs.
CONTENTS
T ransm ission D isassem bly Gear Unit A sse m b ly .................................. 4L80-E-21
Converter A sse m b ly .................................. 4L80-E- 2 Rear Unit End Play C h eck ........................4L80-E-25
Holding F ix tu re .......................................... 4L80-E- 2 Center Support B o lt................................... 4L80-E-25
Speed S en so rs............................................. 4L80-E- 2 Direct Clutch A ssem bly.............................4L80-E-26
Pan and Filter A ssem bly........................... 4L80-E- 3 Intermediate Clutch Assembly and
Wire Harness A ssem bly.............................4L80-E- 3 Front B a n d ...............................................4L80-E-29
Control Valve A ssem bly........................... 4L80-E- 4 Forward Clutch A ssem b ly ........................ 4L 80-E -31
Front and Rear S ervo................................. 4L80-E- 5 Fourth Clutch A ssem b ly ........................... 4L80-E-34
Servo Pin C h e c k .........................................4L80-E- 6 Overdrive Gear U n it.................................. 4L80-E-36
Case Extension A ssem bly......................... 4L80-E- 7 Overrun Clutch A sse m b ly ........................ 4L80-E-36
Parking Lock Pawl and Actuator Overdrive Carrier A ssem bly.....................4L80-E-38
A ssem bly.................................................4L80-E- 7 Turbine Shaft and Overdrive
Front End Play C heck................................4L80-E- 9 Carrier A ssem bly................................... 4L80-E-40
Rear Unit End Play C heck........................4L80-E- 9 Fourth Clutch P la te s .................................. 4L 80-E -41
Pump A ssem bly.......................................... 4L80-E-10 Oil P um p.......................................................4L80-E-42
Overdrive Unit and Front Unit End Play C h e c k ......................4L80-E-46
Fourth Clutch A ssem bly.......................4L 80-E -11 Front Servo A sse m b ly ...............................4L80-E-47
Forward Clutch A ssem bly........................4L80-E-12 Rear Servo Pin C heck................................ 4L80-E-48
Direct Clutch A ssem bly............................ 4L80-E-12 Rear Servo A ccum ulator........................... 4L80-E-49
Intermediate Clutch A sse m b ly ................4L 80-E -12 Control Valve Assem bly/Accum ulator
Center Support and Gear Unit Assembly H o u sin g ................................................... 4L80-E-50
and Rear B a n d ........................................4L80-E-13 Accumulator Housing A ssem bly.............4L80-E-50
Control Valve A ssem bly........................... 4L 80-E -51
C om ponent R e p a ir a n d T ransm ission R eassem bly
Case Extension A ssem bly......................... 4L80-E-57
Transmission C a s e ..................................... 4L80-E-15
Pan and Filter A ssem bly........................... 4L80-E-57
Parking Lock Pawl and Actuator
Speed Sensor A ssem b lies......................... 4L80-E-58
A ssem bly.................................................4L80-E-16
Torque Converter A ssem b ly .....................4L80-E-59
Rear Band and Selective
Disassem bled V iew s.................................. 4L80-E-68
Thrust W asher.........................................4L80-E-17
Bushing and Bearing L ocations...............4L80-E-69
Center Support and
Seal L o c a tio n s ............................................ 4L80-E-70
Gear Unit A ssem bly..............................4L80-E-17
Fastener Tightening Specifications.............4L 80-E -71
Reaction Drum and Carrier A ssem bly.... 4L80-E-19
Special T ools................................................... 4L80-E-72
Center Support A ssem bly......................... 4L80-E-20
7A-17B-2 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
|g | Clean
• Thoroughly clean the exterior of the transmission.
IMPORTANT: It is not recom mended to use air
p o w ered tools to d isa sse m b le d or assem ble
transmissions/transaxles. Improper bolt torques can
contribute to transmission repair conditions and
this information, vital to diagnosis, can only be
detected when using hand tools.
TRANSMISSION DISASSEMBLY
CONVERTER ASSEMBLY
E Remove or Disconnect
1. Torque Converter (1). Figure 1 T ransm ission H old in g Fixture, Base and
2. Install cap on converter hub to hold oil. A d a p te r
SPEED SENSORS
CAUTION: TORQUE CONVERTER IS
EXTREMELY HEAVY (APPROX. 65 LBS.) Figure 2
PERSONAL INJURY MAY RESULT.
|<-»| Remove or Disconnect
03 Inspect
• Filter neck seal (32), replace if necessary.
1. W ire h a rn e s s c o n n e c to rs fro m e le c tr ic a l
components.
NOTICE: Excessive force on the case pass through
connector may damage the connector.
PAN AND FILTER ASSEMBLY
[ 9 | Important
Figure 3
• If the wire harness assembly does not need
E3 Remove or Disconnect servicing, it is not necessary to rem ove it
1. Drain the transmission fluid out case extension from the case.
by rotating transmission to a vertical position. 2. W ire harness assem bly (34) from case using a
2. Seventeen bolts (27), using 10 mm socket, drain 1-5/16" 12 point socket to release the connector
transmission fluid. retaining clips.
Remove or Disconnect
Important
S H 0103-4L80-E
Remove or Disconnect
|^ | Measure
J 2 1 3 7 0 -1 0 ^ ^
B C
u RH0107-4L80-E
RH0109-4L80-E
FOR MODELS
EQUIPPED WITHOUT
NSBU SWITCH
701 PLUG, PARKING PAWL SHAFT HOLE 709 PIN, MANUAL SHAFT RETAINING
702 SHAFT, PARKING LOCK PAWL 710 ACTUATOR ASSEMBLY, PARKING LOCK
703 PAWL, PARKING LOCK 711 LEVER AND PIN ASSEMBLY, INSIDE DETENT
704 RETAINER, PARKING PAWL SHAFT 712 NUT, HEX HEAD
705 SPRING, PARKING PAWL RETURN 713 BRACKET, PARKING LOCK
707 SEAL ASSEMBLY, MANUAL SHIFT SHAFT 714 BOLT, HEX HEAD - M6 X 1.25 X 20.0
708 SHAFT, MANUAL
FOR MODELS
EQUIPPED WITHOUT
NSBU SWITCH
701 PLUG, PARKING PAWL SHAFT HOLE 709 PIN, MANUAL SHAFT RETAINING
702 SHAFT, PARKING LOCK PAWL 710 ACTUATOR ASSEMBLY, PARKING LOCK
703 PAWL, PARKING LOCK 711 LEVER AND PIN ASSEMBLY, INSIDE DETENT
704 RETAINER, PARKING PAWL SHAFT 712 NUT, HEX HEAD
705 SPRING, PARKING PAWL RETURN 713 BRACKET, PARKING LOCK
707 SEAL ASSEMBLY, MANUAL SHIFT SHAFT 714 BOLT, HEX HEAD - M6 X 1.25 X 20.0
708 SHAFT, MANUAL S H 0111-4L80-E
FRONT END PLAY CHECK 4. Pull out turbine shaft (502) while holding output
carrier up with snap ring tool J 28585 as shown
Figures 13 and 14
in Figure 13.
Tool Required: • Increase liftin g force to approxim ately
J 8001 Dial Indicator Set 20 lbs.
J 28585 Snap Ring Tool • Proper end play is 0.102 to 0.559 mm (0.004
to 0.022 inch).
ff] Important
• R e ta in th is m e a s u re m e n t fo r fu tu re
• If end play procedures are not closely adhered reference.
to, incorrect shim thickness will be selected 5. Remove tools.
re s u ltin g in se v ere d a m a g e to in te rn a l
transmission components.
|T1 Important
RH0113-4L80-E
Measure
REMOVE
O-RING J 37789
FIRST
RH0115-4L80-E
PUMP ASSEMBLY
Figures 17 and 18
Tool Required:
J 37789 Pump Rem over
B Remove or Disconnect
1. O-ring turbine shaft (2).
NOTICE: Pum p assembly can not be removed
without damage to the O-ring when in place.
2. S even b o lt and O -rin g a sse m b lie s (3), usin g
13 m m so ck et.
3. A ttach tool J 37789 tightly to pum p shaft with
11 mm w rench.
4. Pump assem bly (4) with seal (5).
5. Tool J 37789.
6. Gasket (6).
7. Selective thrust washer (218). 3 BOLT AND SEAL ASSEMBLY, PUMP TO CASE
• If front end play measurement was incorrect, 4 PUMP ASSEMBLY, COMPLETE
use rem oved washer and chart to select new 5 SEAL, OIL PUMP TO CASE
6 GASKET, PUMP COVER TO CASE
washer.
218 WASHER, THRUST SELECTIVE
RH0117-4L80-E
p *| Remove or Disconnect
1. Snap ring (629).
2. Intermediate clutch backing plate (630).
3. Clutch plates (631 and 632), four each.
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-13
E Remove or Disconnect
NOTICE: Proper torque of center support bolt (25) 25 BOLT, CASE TO CENTER SUPPORT
should be 43 N*m (32 lb. ft.). The original center 26 BOLT, CASE (4TH CLUTCH) RH0123-4L80-E
support (640) can be reconditioned ONE TIM E
only by using J 39919-1 Ream er and a new service Figure 24 4th Clutch Bolt and Center Support Bolt
bolt. If the center support has been previously Location
7A-17B-14 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
640-672
R 73
SH 0124-4L80-E
FOR MODELS
EQUIPPED WITHOUT
NSBU SWITCH
701 PLUG, PARKING PAWL SHAFT HOLE 709 PIN, MANUAL SHAFT RETAINING
702 SHAFT, PARKING LOCK PAWL 710 ACTUATOR ASSEMBLY, PARKING LOCK
703 PAWL, PARKING LOCK 711 LEVER AND PIN ASSEMBLY, INSIDE DETENT
704 RETAINER, PARKING PAWL SHAFT 712 NUT, HEX HEAD
705 SPRING, PARKING PAWL RETURN 713 BRACKET, PARKING LOCK
707 SEAL ASSEMBLY, MANUAL SHIFT SHAFT 714 BOLT, HEX HEAD - M6 X 1.25 X 20.0
708 SHAFT, MANUAL
SH 0110-4L80-E
REAR BAND AND SELECTIVE THRUST WASHER CENTER SUPPORT AND GEAR UNIT ASSEMBLY
Figure 29 Figures 30 and 31
|tjy| Clean
• All Components.
H®] Inspect
1. M ain shaft (662) for:
• Damaged splines.
• Wear.
2. Rear internal gear (666) for:
• Stripped splines.
• Damaged teeth.
• Wear.
3. Output shaft (671) for:
• Stripped splines.
• Damaged teeth.
• Cracks.
• Damaged bushing.
4. Output carrier assembly (661) for:
• Wear.
• Damaged lugs.
• Pinion gear damage.
• Washer wear.
S H 0128-4L80-E
• Pinion gear and pocket thrust surfaces Reaction Drum and Carrier Assembly
damage. Figure 32
|t j|] Measure
[y | Inspect
• Excess pinion washer wear (end play should
be 0.228 to 0.610 mm (0.009 to 0.024 inch) 1. Reaction drum and carrier assem bly (651) for:
using feeler gage. • Pinion gear and pocket thrust surfaces for
damage.
• Cracks or damage to band apply surface.
• Pinion gear damage.
• Planet pinion pin (656) for proper location
(walking).
[^jjj Measure
• Excess pinion washer wear using feeler gage
(end play should be 0.228 to 0.610 mm
(0.009 to 0.024 inch)
2. Roller clutch assembly (644) for:
• Damage to rollers, springs and cage surfaces.
3. Reaction drum spacer ring (645) for:
• Damage.
Assemble
1. Reaction drum spacer ring (645) into reaction
drum (651).
5. Front internal gear ring (658) for: 2. Roller clutch assembly (644) into reaction drum
(651).
• Damage.
• Cracks.
|y | Inspect
6. Thrust washers (659, 673, and 674), bearings
(647 and 664) and races (646, 648, 663, 665, • Sun gear (650) and sun gear shaft (649) for:
and 669) for: - Nicked, scored or worn bushings (676).
• Damage. - Dam aged splines or teeth.
7. Ring output speed sensor (660) for: - Cracks.
• Tightness.
• Damage.
A GAGE, FEELER
651 DRUM AND CARRIER ASSEMBLY,
REACTION RH0130-4L80-E
p g | Clean
• All components.
[F I Inspect
Figure 33
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).
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-21
I? ) Assemble
Figures 33,35 and 36
1. Lubricate new inner and outer clutch piston seals
(637 and 638) and seal pockets in housing with
DEXRON®-III transmission fluid.
2. Seals (637 and 638) on piston (636) with lips
facing away from spring pockets.
3. Clutch piston (636) on center support (640) with
J 21363.
4. Spring and retainer assembly (635) and snap ring
(634), using J 38734 Com pressor Adapter. Align
springs with pockets in housing.
5. New seal rings (639) on new center support hub
(640) using seal tools J 38735.
• Use TRANSJEL™ J 36850 or equivalent to
keep rings (639) tightly sealed.
[~f*| Important
• Cham fered end of J 38735 Seal Sizer to size top
four seals. Start with lower ring, using square 634 RING, SNAP INTERMEDIATE CLUTCH
end o f J 38735 Seal Sizer then work towards 635 SPRING AND RETAINER ASM., INTERMEDIATE CLUTCH
636 PISTON, INTERMEDIATE CLUTCH
top.
637 SEAL, INTERMEDIATE CLUTCH (INNER)
• Pre heat seals (639) prior to installation in hot 638 SEAL, INTERMEDIATE CLUTCH (OUTER)
tap water. 639 RING, OIL SEAL RH0134-4L80-E
pfcl 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™ J 36850
or equivalent.
636 PISTON, INTERMEDIATE CLUTCH 4. Outer race (665), lip up, thrust bearing (664)
640 SUPPORT AND RACE ASSEMBLY, CENTER and inner race (663), lip down onto main shaft
RH0133-4L80-E
(662).
Figure 35 Installing Intermediate Piston Seals 5. M ain shaft (662) and rear internal gear (666)
assembly into output carrier assembly (661).
• L u b ric a te p in io n g e a rs (6 5 5 ) w ith
DEXRON®-III transmission fluid.
6. Output shaft (671) into output carrier assembly
(661).
7A-17B-22 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
SH 0136-4L80-E
|T) Important
• To verify correct assembly, hold reaction carrier
643
(651) stationary. Center support (640) should turn
counterclockwise only.
646
642
LOCATION
OF (643)
SNAP RING
RH0177-4L80-E
7 CASE
633 RING, SNAP CENTER SUPPORT/CASE
640 SUPPORT AND RACE ASSEMBLY, CENTER
673 WASHER, THRUST
662 MAIN SHAFT
S H 0178-4L80-E
| 9 | Important
• DO NOT OVERTORQUE!
R H0115-4L80-E
7 C ASE
25 BOLT, C A S E T O C E N T E R S U P P O R T
S H 0179-4L80-E
ff] Important
p fr] Disassemble
Figures 46 and 47 607 SPRING AND RETAINER ASSEMBLY
608 RING, SNAP
1. Spiral snap ring (627). 623 HOUSING, DIRECT CLUTCH
2. Clutch retainer (626) and race (625).
RH0138-4L80-E
3. Sprag assembly (624).
4. Snap ring (616). Figure 46 Removing Piston Release Spring Retainer
5. Direct clutch backing plate (617) and clutch
plates (611 and 618).
6. Dish plate (609).
7. Snap ring (608) with J 23327-1 and J 25018-A.
8. Spring and retainer assembly (607).
9. Piston (619).
10. Inner seal (605) and outer seal (604) from piston
(619).
11. Center seal (622) from housing (623).
Clean
• All components.
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-27
[jy | Inspect
Figure 47
1. Sprag assembly (624) for:
• Dam aged sprags or cage.
• Distorted springs.
2. Intermediate clutch outer race (625) for:
• Smoothness of inside diameter.
INSPECT • Spline damage.
CHECKBALL 3. Clutch housing (623) for:
537
• Cracks.
• Wear.
• Proper opening of oil passages.
• Checkball (537).
4. Clutch plates (611 and 618) for:
• Wear.
• Burned.
• Flaking.
• Scoring.
• Pitting.
5. Backing plate (617) and piston (619) for:
• Damage.
• Cracks.
6. Spring and retainer assembly (607) for:
• Collapsed coils.
• Distortion.
Assemble
Figures 47 through 54
1. Lubricate clutch piston seals (605, 604 and 622)
and grooves with DEXRON®-III transmission
fluid.
2. Inner seal (605) and outer seal (604) with lips
facing down towards housing onto piston (619).
537 BALL, CHECK 3. Center housing seal (622). Lip seal facing up,
604 SEAL, CLUTCH (OUTER) onto housing (623).
605 SEAL, CLUTCH (INNER) 4. J 21362-1 and J 38732-1 on housing (623).
607 SPRING AND RETAINER ASSEMBLY
608 RING, SNAP 5. Lubricate tools with DEXRON®-III fluid.
609 PLATE, CLUTCH (.054 DISHED) 6. Piston (619) into housing (623) with rotating
611 PLATE ASSEMBLY, CLUTCH m ovement until seated.
616 RING, SNAP (6.24 O.D. X .062)
617 PLATE, DIRECT CLUTCH BACKING 7. S p rin g and re ta in e r a sse m b ly (6 0 7 ) w ith
618 PLATE, CLUTCH (.0915 FLAT) J 23327-1 and J 25018-A.
619 PISTON, DIRECT CLUTCH 8. Snap ring (608).
622 SEAL, CLUTCH (CENTER)
623 HOUSING, DIRECT CLUTCH
624 SPRAG ASSEMBLY, INTERMEDIATE CLUTCH
625 RACE, INTERMEDIATE CLUTCH (OUTER)
626 RETAINER, INTERMEDIATE CLUTCH
627 RING, EXTERNAL LOCKING
RH0139-4L80-E
Q —
GROOVES
UP 626
Figure 48 Installing Direct Clutch Piston
625
624
623
Install or Connect
E
Figures 50 through 53
IMPORTANT: Dip all clutch plates in DEXRON®-
III transmission fluid prior to assembling, to aid
lubrication during start up.
1. Sprag assembly (624).
2. Intermediate clutch race (625), grooves up, with
clockw ise m otion. The direct clutch housing
should not rotate counterclockwise.
Figure 51 Sprag Assem bly Test
3. Intermediate clutch retainer (626).
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-29
RH0143-4L80-E
640
Figure 52 Direct Clutch Plate Chart
Inspect
616 617 619 607 608 605 622 611 618
1. Clutch plates (631 and 632) for:
604 SEAL, CLUTCH (OUTER)
605 SEAL, CLUTCH (INNER) • Wear, pitting, flaking or cracks in lining.
607 SPRING AND RETAINER ASSEMBLY • Discoloration, scoring or cracks.
608 RING, SNAP
609 PLATE, CLUTCH (.054 DISHED) 2. Backing plate (630) for:
611 PLATE ASSEMBLY, CLUTCH • Burrs and dirt.
616 RING, SNAP (6.24 O.D. X .062)
617 PLATE, DIRECT CLUTCH BACKING 3. Front band (628) for:
618 PLATE, CLUTCH (.0915 FLAT) • Wear, pitting, flaking or cracks in lining.
619 PISTON, DIRECT CLUTCH
622 SEAL, CLUTCH (CENTER)
Assemble
623 HOUSING, DIRECT CLUTCH
624 SPRAG ASSEMBLY, INTERMEDIATE CLUTCH
625 RACE, INTERMEDIATE CLUTCH (OUTER) NOTICE: Dip all clutch plates in DEXRON®-III
626 RETAINER, INTERMEDIATE CLUTCH transmission fluid.
627 RING, EXTERNAL LOCKING RH0144-4L80-E
1. Steel plates (632) and composition plates (631)
Figure 53 Direct and Intermediate Sprag Clutch alternately, starting with a steel plate.
Assembly 2. Intermediate clutch backing plate (630). Flat side
down.
Measure 3. Snap ring (629), medium size, at the nine o ’clock
Figure 54 position.
HYDRA-MATIC 4L80-E
CLUTCH PLATE APPLICATION CHART
INTERMEDIATE CLUTCH
NO. OF NO. OF NO. OF PISTON
FLAT STEEL DISHED COMPOSITION TRAVEL
MODELS PLATES PLATES PLATES CHECK
THICKNESS 1.97MM
(.077’ ) 1.02-2.72MM
(0.040-0.107")
ALL MODELS 4 4
R H0180-4L80-E
RH0181-4L80-E
Assemble
J 21362-1
J 38732-1
| V | Important
• D ip c lu tc h p la te s in D E X R O N ® -III
transmission fluid.
17. Direct clutch hub (615) in forward clutch housing
(602).
18. Snap ring (616).
HYDRA-MATIC 4L80-E
CLUTCH PLATE APPLICATION CHART
FORWARD CLUTCH
NO. OF NO. OF NO. OF NO. OF PISTON
FLAT STEEL DISHED COMPOSITION WAVED STEEL TRAVEL
PLATES PLATES PLATES PLATES CHECK
MODELS
1.97MM 1.37MM 2.03MM 1.54MM 3.07-
THICKNESS
(.0775') (.054-) (.080’ ) (.0605") 4.27MM
(0.121-
ALL MODELS 0.186')
5 1 5
EXCEPT ZFP
2.209-
3.81 MM
ZFP 4 5 1
(0.087-
A AIR SUPPLY
0.150") 502 SHAFT, TURBINE
602 HOUSING ASSEMBLY, FORWARD CLUTCH
RH0149-4L80-E 615 HUB, DIRECT CLUTCH DRIVING
616 RING, SNAP (6.24 O.D. X .062)
Figure 62 Forward Clutch Plate Chart RH0150-4L80-E
Install or Connect
ES Disassemble
Figure 64 Figure 65
• F o rw a rd c lu tc h a sse m b ly (6 0 2 ) u sin g 1. Snap ring (523).
J 38358-A. 2. Backing plate (524) and clutch plates (525 and
526). Four of each.
NOTICE: When installed correctly the top of speed
se n so r ring to the pum p g a sk et su rfa c e is 3. Install tools J 38882 and J 23327-1, and compress
approximately 98-99 mm or 3.85-3.89 inches. spring retainer assembly.
4. Snap ring (533) and spring retainer assembly
(532).
5. Fourth clutch piston (528) and outer seal (527).
6. Housing (529) and inner seal (531).
19| Clean
J 38358-A • All components.
|^ | Inspect
• 4th clutch housing orifice cup plug (530). Orifice
is open approximately 0.51 mm (0.020 inch).
[y | Inspect
Figure 68
• Place 4th clutch assembly (529) with the spring
and retainer assembly (532) facing up.
I^jll Measure
• Place feeler gage betw een backing plate (524)
and snap ring (523). M easurem ent should be
1.016 to 2.540 mm (0.040 to 0.100 inch).
m Important
• Remove snap ring (523), 4th clutch backing plate
(524), 4th plate clutch assemblies (525) and 4th
clutch plates (526) from 4th clutch housing
assem bly (529) to ease assem bly o f overrun
clutch housing assembly (504).
□ Install or Connect
Figure 6 7
1. 4th clutch assem bly (529) into case (7).
Assemble 2. New 4th clutch bolt (26) through case fluid
passages into 4th clutch housing (529) and rotate
Figure 66 transmission to horizontal position.
1. 4th clutch outer seal (527) onto piston (528) and Tighten
4th clutch inner seal (531) into housing (529).
2. Place seal protector J 38731 -1 onto housing (529) • Bolt (26) to 23-26 N«m (17-19 lb. ft.).
through small end.
3. Place seal protector J 38731-2 onto piston (528) | 9 | Important
through large end. • DO NOT OV ERTO RQ U E!
4. Place spacer J 38731-3 inside o f piston (528).
5. Place housing (529) on bench resting on piston
(528) and piston spacer.
6. Push and rotate down on housing (do not force)
until piston is through housing, exposing snap
ring groove.
7. Rem ove housing seal protector J 38731 -1.
8. P lace snap ring (533), spring and reta in e r
assembly (532) onto piston (528).
9. Com press spring and retainer assembly using
J 38882 Adapter and J 23327-1.
10. Install snap ring (533).
11. Remove tools.
12. Turn assembly over and install 4 of each clutch
plates (525 and 526) alternating steel and fiber 7 CASE
plates. Starting with steel first. Locate steel plate 26 BOLT, CASE (4TH CLUTCH)
529 HOUSING, 4TH CLUTCH
index notch opposite 4th clutch bolt hole. RH0183-4L80-E-R1
523 524
[<$»| Disassemble
Figure 70
1. Snap ring (511).
2. Backing plate (510).
3. Clutch plates (508 and 509) (three steel and three
fiber).
4. Com press spring and retainer assembly (506)
using J 23327-1 and J 38734 adapter.
5. Snap ring (507).
6. Remove tools.
7. Spring and retainer assem bly (506).
8. Piston (505).
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-37
|nfr| Assemble
Figures 71 and 73
1. Piston seal protector J 38729 into housing (504).
2. Piston and seal assembly (505) into housing (504)
while rotating.
NOTE: Piston must be kept level while rotating.
3. Compress spring and retainer assembly (506)
(springs facing dow n) using J 23327-1 and
J 38734.
4. Place snap ring (507) on housing (504).
5. Clutch plates (508 and 509), 3 of each, backing
plate (510).
6. Snap ring (511).
p y l Clean
• All components.
• Piston (505) should not be cleaned with solvent.
[ffi Inspect
1. Clutch plates (508 and 509) for:
• Burning.
• Scoring.
• Flaking.
• Pitting.
• Wear.
7A-17B-38 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
1. Feeler gage between backing plate and snap ring. fl|1 Measure
2. Clearance should be between 0.838 to 2.38 mm 1. M ount J 8001 on the rod and index it to the
(0.033 to 0.094 inch.) pinion (518). Set indicator to “0”.
2. M anually raise pinion.
3. End play is 0.229 to 0.610 mm (0.009 to 0.024
inch).
A GAGE, FEELER
504 HOUSING ASSEMBLY, OVERRUN CLUTCH
510 PLATE, OVERRUN CLUTCH BACKING
511 RING, SNAP R H0157-4L80-E
|«y»| Disassemble
Figures 75 and 76
1. Snap ring (521) and retainer pinion pin (520).
NOTE: M ark top of pinion gears and location on
carrier of pins to be reinstalled in original locations.
504 HOUSING ASSEMBLY, OVERRUN CLUTCH
2. Four pinion pins (519) from carrier (514).
505 PISTON ASSEMBLY, OVERRUN CLUTCH
506 SPRING AND RETAINER ASSEMBLY 3. Pinions (518), thrust washers (515 and 516) and
507 RING, SNAP RETAINER roller needle bearings (517).
508 PLATE, OVERRUN CLUTCH
509 PLATE ASSEMBLY, OVERRUN CLUTCH
510 PLATE, OVERRUN CLUTCH BACKING |g | Clean
511 RING, SNAP RH0158-4L80-E
• All components.
Figure 73 Overrun Clutch Assem bly
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-39
Inspect
0
1. Pinion pocket thrust surfaces for:
• Burrs.
2. Roller clutch assembly (512).
3. Pinion assembly (518).
4. Thrust bearing assembly (513).
5. Carrier (514) for:
• Cracks.
• Damage.
• Wear.
Assemble
1. Needle bearing (517) and pinions (518).
2. Washers (515 and 516) on pinion (518).
|~jH Important
• Thrust bearing (513) must be installed before
pinions.
3. Thrust bearing (513).
4. Pinion gear assemblies into carrier (514).
5. Pinion pins (519) through pinion gear (518) and
carrier (514).
6. Retainer (520) and snap ring (521).
512 ROLLER CLUTCH ASSEMBLY, OVERDRIVE
513 BEARING ASSEMBLY, THRUST CARRIER/ OVERRUN
CLUTCH
514 CARRIER ASSEMBLY, OVERDRIVE
515 WASHER, PINION THRUST
516 WASHER, PINION THRUST (STEEL)
517 ROLLER, NEEDLE BEARING
518 PINION, OVERDRIVE PLANET
519 PIN, OVERDRIVE PINION
520 RETAINER, PINION PIN
521 RING, SNAP RH0161-4L80-E
X111 ----
T -519
515
RH0162-4L80-E
OIL PUMP
Figure 83
❖ Disassemble
1. Five bolts (220) and vent shield (239).
CAUTION: Valve springs can be tightly
compressed. Use care when removing
retainers and plugs (226). Personal injury
could result.
2. Retaining ring (226).
3. Pressure regulator valve assembly (227 thru 231,
232 and 211).
4. Converter limit valve assembly pin (211), plug
(212), spring (213) and valve (214).
5. Torque converter clutch enable valve assembly
sleeve (215), spring (216) and valve (217).
6. Torque converter clutch valve assembly snap ring
(221), plug (232), valve (223), spring (224), plug
(225) and pin (211).
7. Inspect identification dots on face of drive gear
before rem oving gears (204) and (205) from
pum p body, to ensure gears w ere installed
correctly.
8. Pump drive gear (205) and driven gear (204).
9. Seal rings (219) and selective thrust w asher
(218).
10. Seal ring (5) pump to case.
Pump Body
524 PLATE, 4TH CLUTCH BACKING
Figure 83
525 PLATE ASSEMBLY, 4TH CLUTCH
526 PLATE, 4TH CLUTCH [y ] Inspect
1. Gear pockets, crescent, pump body face, and
Figure 81 Installing Fourth Clutch Plates bushing for:
• Scoring.
• Nicks.
• Wear.
2. Oil passages for:
• Foreign material or debris.
• Porosity.
• Scored or irregular mating surfaces.
• Cross channel leaks.
3. Pump body bolt threads for:
• Damage.
4. Oil seal (201), bushing (202) for:
• Wear.
• Damage.
523 RING, SNAP (4TH CLUTCH)
529 HOUSING, 4TH CLUTCH RH0186-4L80-E |*--»| Remove or Disconnect
Figure 82 Installing Fourth Clutch Snap Ring 1. Pump body seal assembly (201) using J 23129.
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-43
[y | Inspect |^ | Assemble
1. Pump gear faces for: 1. Driven gear (204) and drive gear (205) with
• Wear. identification dots facing up (Figure 84).
• Scoring. • Install driven gear (204) into body.
2. Stator shaft splines for: • Lubricate drive gear (205) and driven gear
• Damage or stripped splines. (2 0 4 ) w ith D E X R O N ® -III a u to m a tic
3. Stator shaft bushings (233) and (234) for: transmission fluid.
• Wear. • Install drive gear (205) into pum p body
(203) with identification dots facing up.
• Galling.
4. Oil ring grooves for: [T 1 Important
• Nicks.
• Be sure to assemble the drive gear with the
• Burrs. identification dots up as shown in Figure 84
• Debris. to ensure correct orientation of the drive
5. Pressure regulator assembly, converter limit valve flats.
assembly, TCC enable valve assembly and TCC
2. Pressure regulator valve (231) into bore.
valve assembly for:
3. Bore plug (232) and valve assembly pin (211).
• Free m ovem ent of valves in bores.
4. Springs (230 and 238) and retainer (229) in
• Chips. pressure regulator bore.
• Burrs. 5. Regulator boost valve (228) into boost valve
• Distortion. bushing (227), stem out against spring (230).
• Plugged oil passages. 6. Snap ring (226).
6. Breather hole in pump cover blocked (Figure 7. Converter limit valve (214), spring (213), plug
85). (212) and valve assem bly pin (211).
8. TCC enable valve (217), spring (216), compress
spring down and insert a small rod into hole A
[jy l Clean
(see Figure 85) to hold down spring until sleeve
• All components. (215) is installed. Pull out rod when sleeve is
installed.
9. TCC valve plug (225), pin (211), load from other
Pump Assembly end of bore, spring (224), valve (223), plug (232)
and snap ring (221).
Figures 84 through 89
Tools Required [jy | Inspect
J 38694 Pum p Seal Installer • Pressure regulator assembly, converter limit
J 21368 Alignment Band valve, TCC enable valve, and TCC valve
for free m ovem ent of valves in bores.
J 38739 Oil Pump Seal Ring Installer, Sizer
and Pusher 10. Cover (206) on body (203).
J 25025-1 Guide Pins 11. Vent shield (239) and five bolts (220).
J 37789 Pum p - Install/Remove • Finger tight only at this time.
• Install shield at location shown in Figure
[^ 1 Measure 85. Round end on shield fits into hole in
pump cover. Slotted hole in shield fits under
• M easure clearance between gears and body.
bolt head.
- Side clearance 0.017 to 0.071 mm (0.0007
to 0.0028 inch.).
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-45
[Y] Important
Tighten
• Five bolts (220) to 24 N*m (18 lb. ft.)
13. Oil seal (5).
NOTICE: Coat the pump to case O-ring seal (5)
with TRANSJEL™ or petroleum jelly. This will
ease drawing the pump into the case, and prevent
seal damage.
14. C o rre c t s e le c tiv e th ru s t w a sh e r (2 1 8 ) as
determined by Front End Play Check during
disassem bly. U se TRANSJEL™ J 36850 or
equivalent to hold in place.
A 0.017MM - 0.071 MM (0.0007" - 0.0028")
B IDENTIFICATION MARKS 15. Two solid oil seals (219). Using J 38739 installer
203 BODY, OIL PUMP pusher and sizing tool onto pump hub.
204 GEAR, PUMP DRIVEN
205 GEAR, PUMP DRIVE R H0166-4L80-E IT l Important
Figure 84 Measuring Pump Body Face To Gear Face • Be sure to use small cham fer end of sizer
Clearance J 38739 to do the lower ring. Then use larger
chamfered end to size other seal.
BREATHER HOLE
J 25025-1
J 21368
J 25025-1
B Install or Connect
1. Gasket (6) on transm ission 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
toward the bottom pan).
3. Seven bolt and seal assemblies (3) and seal (2).
Tighten
2 SEAL, O-RING (TURBINE SHAFT/TURBINE HUB)
• Bolts (3) to 24 N m (18 lb. ft.). 3 BOLT AND SEAL ASSEMBLY, PUMP TO CASE
4 PUMP ASSEMBLY, COMPLETE
|T| Important 5 SEAL, OIL PUMP TO CASE
6 GASKET, PUMP COVER TO CASE
• If turbine shaft cannot be rotated as pum p 218 WASHER, THRUST SELECTIVE
assembly is being pulled into place, the overrun, 219 RING, OIL SEAL
R H0188-4L80
4th, forward and/or direct clutch housings have
not been installed properly to index with all the Figure 89 Gasket and Pump Assembly
clutch plates. This condition must be corrected
before pum p assembly is fully installed.
4. Install seal assem bly (201) using J 38694, if FRONT UNIT END PLAY CHECK
necessary. Figures 90 and 91
Tools Required:
J 8001 Dial Indicator Kit
J 28585 Snap Ring Tool
m Important
ftjj] Measure
1. Attach J 8001 rod to one of the bolt holes on the
THICKNESS (INCH) STRIPE
transmission case (7).
2. M ount J 8001 on the rod and index it to the end .057 - .061 BLUE
of the turbine shaft. Set dial to “0”. .073 - .077 RED
3. Eliminate slack by pressing down on turbine shaft .089 - .093 BROWN
(502) and with J 28585 up on output carrier.
.105- .109 GREEN
Then pull up with 3 to 5 lbs. of force on turbine
shaft to eliminate any clearance between snap .121 - .125 PLAIN
ring (522) and overdrive carrier (514).
4. Pull out turbine shaft (502) while holding output R H0113-4L80-E
carrier up.
• Increase lifting force to approxim ately 20 Figure 91 Selective Thrust Washer (218)
lbs.
• Proper end play is 0.102 to 0.559 mm (0.004
FRONT SERVO ASSEMBLY
to 0.022 inch).
5. Rem ove tools and correct end play if necessary. Figure 92
6. Install O-ring (2) on turbine shaft. Clean
All components.
]p Inspect
1. Front servo piston (58) for:
• Porosity or damage.
• Seal and seal ring groove for damage.
2. Piston pin (55) for:
• Wear.
3. Spring (60) for:
• Distortion.
4. Servo bore for:
• Wear or scoring.
Assemble
E3 Install or Connect
• Front servo assembly into case (7).
- M ake certain tapered end of piston pin (55)
contacts band.
[||] Measure
Tighten
J 38737
J 21370-10
R H 0107-4L80-E
Inspect
1. Rear Accum ulator piston (68) and Rear Servo
piston (65) for:
• Porosity or damage.
• Ring groove damage.
2. Seals (66, 67 and 69) for:
• Nicks or cuts.
3. Cover (62) for:
• Porosity.
• Scored or damaged.
4. Springs (71 and 74) for:
• Distortion.
• Damage.
5. Pin (73) for wear.
6. Servo bore for w ear or scoring.
Clean
• All components.
Assemble
1. Rear servo spring retainer (72), rear servo spring
(71) and servo washer (70) on rear band apply
pin (73).
2. Reverse servo piston seal (66) on rear servo
piston (65) and press onto rear band apply pin
(73).
3. Retaining ring (64).
4. Lube seals, inner (69) and outer (67) before
in s ta llin g a c c u m u la to r p is to n se a ls on
accum ulator piston (68). Place in rear servo
piston.
□ Install or Connect
1. Rear accum ulator spring (74) in case bore.
REAR SERVO ACCUMULATOR 2. Correct rear servo parts (64-73) in servo bore.
3. New gasket (63), cover (62) and six 10 mm
Figure 96
bolts (61) using 10 mm socket.
Disassemble
Tighten
Retaining clip (64) from rear band apply pin • Bolts (61) to 24 N»m (18 lb. ft.).
(73) and inspect.
Reverse servo piston seal (66), rear servo piston
inner (69) and outer (67) seals.
7A-17B-50 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
Clean
Control valve assembly and accumulator housing
(51) thoroughly in clean solvent.
Air dry.
Clean
• All components.
61 BOLT, REAR SERVO COVER
62 COVER, REAR SERVO jy Inspect
63 GASKET, REAR SERVO COVER
64 CLIP, RETAINING (BOTTOM) All valves, pistons, springs and seals for:
65 PISTON, REAR SERVO • Porosity.
66 RING, OIL SEAL ACCUM. PISTON (OUTER)
67 RING, OIL SEAL ACCUM. PISTON (INNER) • Scoring.
68 PISTON, REAR ACCUMULATOR • Nicks.
69 SEAL, REVERSE SERVO PISTON
70 WASHER, SERVO PISTON • Scratches.
71 SPRING, REAR SERVO
72 RETAINER, REAR PISTON SPRING
73 PIN, REAR BAND APPLY (SELECTIVE)
74 SPRING, REAR ACCUMULATOR
RH0170-4L80-E
SH 0173-4L80-E
[~f~| Important
Tighten
Figure 101 Checkball Location Figure 102 Installing Control Valve Assem bly
7A-17B-56 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
Figure 103 Bolt Tighten Sequence, Control Valve Assem bly and Switch Assem bly Fluid Pressure
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-57
|y | Inspect
Install or Connect
E
1. O-ring and orifice assem bly (12) to rear of case.
2. Seal (13) with J 38693 and snap ring (14) into
rear o f case.
3. O-ring (15) onto extension assembly.
4. Extension assembly (19).
5. Six bolts (21) using 15 m m socket.
[^ 1 Tighten
• Bolts (21) to 34 N*m (25 lb.ft.)
6. New rear seal (20) with J 38694 or J 38869.
• Apply TRANSJEL™ J 36850 or equivalent
to spring pocket.
□ Install or Connect
1. Two speed sensor and bracket assemblies (22)
onto case (some models).
2. Two bolts (23) using 8 m m socket.
3. Case oil test plug (24) (if removed).
|[^ | Tighten
• Bolts (23 and 24) to 11 N m (97 lb. in.).
R H0195-4L80-E
SH0173-4L80-E
49 SPRING, 4TH CLUTCH ACCUM. PISTON 404 SEAL, (1.615) SQUARE CUT
50 SPRING, 3RD CLUTCH ACCUM. PISTON 405 PISTON, 3RD CLUTCH ACCUMULATOR
51 HOUSING, ACCUMULATOR 406 SEAL, (.859) SQUARE CUT
53 BOLT, ACCUM. HOUSING TO VALVE BODY 407 PISTON, 4TH CLUTCH ACCUMULATOR
402 RING, SNAP 408 PIN, 4TH CLUTCH ACCUMULATOR PISTON
R H0196-4L80-E-R1
R H0197-4L80-E
662 663 664 665 666 648 647 66g 67q 677 67 7
4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-17B-67
O u U I v/27 * fL O U t
FOR MODELS
EQUIPPED WITHOUT
NSBU SWITCH
701 PLUG, PARKING PAWL SHAFT HOLE 709 PIN, MANUAL SHAFT RETAINING
702 SHAFT, PARKING LOCK PAWL 710 ACTUATOR ASSEMBLY, PARKING LOCK
703 PAWL, PARKING LOCK 711 LEVER AND PIN ASSEMBLY, INSIDE DETENT
704 RETAINER, PARKING PAWL SHAFT 712 NUT, HEX HEAD
705 SPRING, PARKING PAWL RETURN 713 BRACKET, PARKING LOCK
707 SEAL ASSEMBLY, MANUAL SHIFT SHAFT 714 BOLT, HEX HEAD M6 X 1.25 X 20.0
708 SHAFT, MANUAL
S H 0 1 1 1-4L80-E
S H 0200-4L80-E
7A-17B-69
535 BUSHING, OVERRUN CLUTCH HSG. 679 BUSHING, 1.536" DIA. X 3.52
536 BUSHING, 1.12" O.D. X 0.50“ 681 BUSHING, REACTION DRUM
7A-17B-70
SOME
MODELS
PAN TO CASE....................................................................................... 24 18 —
EXTENSION HOUSING TO CASE...................................................... 34 25 —
FLYWHEEL TO CONVERTER............................................................... 44 32 —
RH0203-4L80-E-R1
7A-17B-72 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
SPECIAL TOOLS
Overrun Clutch Piston Seal Protector Rear Lube Seal Installer Compressor Adapter
(Used with J 23327-1)
Forward Clutch Spring Compressor Oil Pump Seal & Rear Extension Housing Gear Unit Assembly Installer/Remover
Seal (Fixed Yoke) Installer (Used with J 6125-1B)
Intermediate Clutch Inner Seal Protector Direct Clutch Spiral Snap Ring Placer
5/16-18 Thread with 3/8-16 Adapter Support Adapter Forward Clutch Assembly Remover &
(Set of 2) (Used with J 6116-01) Installer
Dial Indicator Set Pump Body and Cover Alignment Band Pump Removal Tool
J 21368 J 37789
Dial Indicator Stand and Guide Pin Set Band to Apply Pin Gauge Converter End Play Tool
(Used with J 38737)
J 26900-13 J 38737
SIZER
J 38731-1 J 38731-2 J 38731-3 J 38734 J 38739
Direct & Forward Clutch Piston & Seal Center Support Seal Fourth Clutch Spring & Retainer
Protectors Installer/Sizer/Pusher Assembly Adapter
INSTALLER
O UTER
Direct Clutch Assembly Turbine Shaft Seal Installation Kit Torque Converter Leak Test Fixture
Remover/Installer INSTALLER INSTALLER
J 38736-1 J 38736-2
SIZER SIZER
J 38733 J 21369-E
Assembly Lubricant
J 38736-3 J 38736-4 125c PLUG 1.625" PLUG 1.375" PLUG
PUSHER PUSHER
Center Support Reamer and Pin Gage Torque Converter Holding Strap
c
J 39919-1 J 39919-2 J 21366
SH0205-4L80-E
7A-17B-74 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR
SECTION 7B6
BORG-WARNER T5 MANUAL
TRANSMISSION
NOTICE: When fasteners are removed, always reinstall them at the sam e location from which they were
removed. If a fastener n eed s to be replaced, u se 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. Fasteners that are not reused, and those requiring thread locking com pound will be called out.
The correct torque value m u st be u se d when installing fasteners that require it. If the above conditions
are not followed, parts or sy ste m damage could result.
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................7B6- 1
Precautions............................................................................................................................................................. 7B6- 2
Unit Disassembly......................................................................................................................................................7B6- 3
Transmission Disassembly..................................................................................................................................7B6- 3
Mainshaft Disassembly........................................................................................................................................ 7B6- 5
Drive Gear Disassembly......................................................................................................................................7B6- 6
Cleaning and Inspection......................................................................................................................................7B6- 7
Transmission C ase........................................................................................................................................... 7B6- 7
Bearing Rollers and Spacers......................................................................................................................... 7B6- 7
Front and Rear Bearings................................................................................................................................ 7B6- 7
Synchronizer Blocker Rings........................................................................................................................... 7B6- 8
Synchronizer Keys and Springs........................................................................................................................7B6- 9
Extension Housing Oil Seal and Bushing Replacement............................................................................ 7B6- 9
Drive Gear Bearing Retainer Oil Seal.............................................................................................................. 7B6-10
Transmission Cover............................................................................................................................................. 7B6-10
Front Countershaft Bearing............................................................................................................................... 7B6-11
Unit Assem bly........................................................................................................................................................... 7B6-12
Drive Gear Assem bly........................................................................................................................................... 7B6-12
Mainshaft Assembly............................................................................................................................................. 7B6-13
Transmission Assembly.......................................................................................................................................7B6-13
Specifications............................................................................................................................................................ 7B6-15
Fastener Tightening Specifications...................................................................................................................7B6-15
Lubrication Specifications...................................................................................................................................7B6-15
Special Tools............................................................................................................................................................. 7B6-16
GENERAL DESCRIPTION
The 77-mm 5-speed is a constant mesh transmission, • Thrust washers limit the play of the counter
synchronized in all speeds except reverse. shaft.
The main components are: • An extra gear is mounted to the countershaft for
1. Main drive gear. 5th speed.
• An integral shaft is splined to engage with the
3. Mainshaft.
clutch-driven plate.
• The gear drives the countershaft. • The drive gears rotate freely on the mainshaft
• A tapered bearing supports the shaft in the and are in constant mesh with the countershaft.
case. • Key-type synchronizers engage the gears.
2. Countershaft. • The first and second synchronizer hub is
• The countershaft is one unit for constant rota machined in place.
tion with the drive gear. • A tapered bearing supports the mainshaft in the
• Bearings support the countershaft in the case. rear of the case.
7B6-2 BORG-WARNER T5 MANUAL TRANSMISSION
UNIT DISASSEMBLY
TRANSMISSION DISASSEMBLY 2. Pin from the offset lever (figure 3).
3. Extension housing to transmission case bolts.
Remove or Disconnect (Figures 3 through 15) 4. Extension housing and the offset lever.
Figure 8— Fifth Gear and Reverse Shift Rail Figure 10—Main Drive Gear Shim Pack
J 22912-01
8433
Figure 16— Removing the Third and Fourth Figure 18—Three Piece Blocker Ring
Synchronizer
Inspect BEARING ROLLERS AND SPACERS
1*
1. Gear teeth and shaft pilot for wear. IP Inspect
CLEANING AND INSPECTION • Drive gear bearing rollers for chips, cracks, or
excessive wear and replace if necessary.
TRANSMISSION CASE
• Reverse idler shaft for wear and damage
Clean • Spacers for wear.
1. Transmission case thoroughly inside and outside FRONT AND REAR BEARINGS
with appropriate solvent.
2. Magnetic disk at the bottom of the transmission Clean
case.
1. Front and rear bearings thoroughly with appropriate
L* Inspect solvent.
2. Blow out bearings with compressed air.
1. Case for cracks.
2. Front and rear faces of the transmission case for • Do not allow the bearings to spin. Turn them
burrs, and if present, dress them off with a fine mill slowly by hand. Spinning bearings may damage
file. the race and rollers.
7B6-8 BORG-WARNER T5 MANUAL TRANSMISSION
Figure 19—Main Drive Gear Bearings Figure 21—Measuring Blocker Ring Wear
material. The third-fourth synchronizer blocker
ring has friction material. Assembling one in
place of the other will result in serious damage
to the transmission.
L* Inspect
V Inspect
Important
Tool Required:
J 8092 Driver Handle
J 23062-14 Extension Housing Bushing Remov
er and Installer
1. Seal.
2. Sealing compound from the flange of the extension
Figure 23—First-Second Synchronizer Assembly housing.
7B6-10 BORG-WARNER T5 MANUAL TRANSMISSION
Inspect
Tools Required:
J 8092 Driver Handle
J 21426 Extension Housing Oil Seal Installer
J 2 3 0 6 2 -1 4 Extension Housing Bushing
Remover and Installer
1. New bushing if needed, using J 8092 and
J 23062-14 (figure 26).
• Coat the bushing with transmission oil.
• Drive the bushing into the extension.
2. Locking compound on the outside of a new seal.
3. New seal using J 21426 (figure 27).
Figure 27—Installing the Extension Housing Oil
• Lubricate inside diameter of seal with transmis
Seal
sion oil.
1. Seal.
2. Sealing compound from flange of retainer.
i? Inspect
Tool Required:
J 37375 Bearing Retainer Seal Installer
TRANSMISSION COVER
* Disassemble (Figure 29)
5. Remove the inserts and shift fork plates from the FRONT COUNTERSHAFT
forks. BEARING
• Note the position of inserts and plates for reas
sembly. *■■* Remove or Disconnect (Figures 30 and 31)
^ Clean
Tools Required:
J 37358-1, -2 Bearing Race Receiver and Case
• All metal parts in solvent and air dry. Support
J 22912-01 Bearing and Gear Puller
I? Inspect
J 37359 Countershaft Bearing Remover
J 8092 Universal Driver Handle
1. Shift forks.
• For damage or bends. Important
• For worn inserts.
2. Shift rail. • Failure to support the case properly will result in
• For damage and bends. permanent distortion of the case during bearing
• For worn or damaged plates. race removal.
• For smooth fit in the cover. 1. Countershaft front bearing race and O-ring from the
3. Transmission cover. transmission case using J 37358-1 with J 37358-2
• For cracks and warping. with a press (figure 30).
• For smooth shift rail fit.
• Shaft plug for damage or leaks.
Figure 31—Removing Bearing from the Figure 32—Front Countershaft Bearing Assembly
Countershaft
• Remove the front countershaft bearing race
only if it is worn or damaged.
2. Countershaft front bearing from the countershaft
using J 22912-01 with J 37359, J 8092 and a press
(figure 31).
Tools Required:
J 37357 Countershaft Bearing and Race
Remover and Installer
J 22912-01 Bearing and Gear Puller
J 8092 Universal Driver Handle
1. Countershaft front bearing onto the countershaft
using J 37357 with J 22912-01, J 8092, and a
press.
2. New O-ring onto the countershaft front bearing
race (figure 32).
• Lubricate the O-ring. • Lightly tap the race into its bore until the O-ring
3. Countershaft front bearing race into the transmis is compressed.
sion case using J 37357 with J 8092 and a press • Use a press to install the race until its shoulder
(figure 33). rests on the inside of the case.
UNIT ASSEMBLY
Use new seals, gaskets, and thread sealer on all bolt DRIVE GEAR ASSEMBLY
threads when assembling the transmission. Tighten all
bolts to specified torque.
Lubricate all assemblies as they are installed in the * Disassemble (Figure 19)
transmission using Dexron® III automatic transmission
fluid oil or equivalent. Tools Required:
J 22912-01 Bearing and Gear Puller
J 6133-01 Installer
BORG-WARNER T5 MANUAL TRANSMISSION 7B6-13
1. Bearing onto the drive gear using J 22912-01 with 14. Third gear spacer and needle bearing assembly.
J 6133-01 and a press. • Make sure the bearing spacer is not trapped
• Coat roller bearings and drive gear bearing bore between the gear face and snap ring. The spac
with lightweight grease. er runs inside the gear bore.
15. Third-fourth synchronizer, third blocker ring, sleeve,
2. Roller bearings into the bore of the drive gear.
hub, and third gear as an assembly using J 37372
3. Thrust bearing and race into the drive gear.
and a press.
16. Thrust bearing and race to the front end of main
MAINSHAFT ASSEMBLY shaft.
Disassemble (Figure 9)
* Important
3. Rear countershaft bearing race. 11. Temporarily install front bearing retainer.
4. Reverse idler gear and the shaft (figure 14). • Be sure to align the marks made during disas
• Hold the gear in the case with the shift lever sembly.
groove to the rear. 12. Fifth gear on countershaft.
• Install the reverse idler shaft from the rear.
• Slide shift rail and fifth gear shift fork assembly
• Install a new retaining pin.
into case.
5. Countershaft retainer to transmission housing with • Align reverse shift fork and slide rail through
out shims (figure 13). fork.
• Position lever return spring in case with long
Tighten end of spring to the rear, and slide rail through
the spring.
•Countershaft retainer bolts to 20 N-m (15 lbs.
13. Blocker ring and fifth gear synchronizer in fifth gear
ft.). shift fork.
• Slide fork rail assembly and synchronizer into
€ Measure
position.
• Countershaft end play using dial indicator 14. Fifth gear synchronizer retainer and snap ring (fig
J 8001 (figure 35). ure 7).
• Remove retainer and install shim(s) as neces 15. Oiling funnel into rear of countershaft (figure 5).
sary to provide proper end play. Zero end play 16. Fifth gear and reverse shift lever in the case (figure
with no preload is ideal, but up to 0.10 mm 8 ).
(0.004 inch) end play is allowable. Do not • Make sure reverse shift fork pin and fifth-gear
preload bearing with shim(s) larger than original shift rail pin are engaged with shift lever.
end play measurement. 17. Fifth gear and reverse lever pivot bolt and retaining
Reinstall retainer and bolts. clip (figure 6).
• Coat pivot bolt threads with pipe sealant GM
& Tighten P/N 1052080 or equivalent.
St Tighten
$ Tighten
Measure
SPECIFICATIONS
FASTENER TIG H TEN IN G SPECIFICATIONS
N-m Lbs. Ft. Lbs. In.
Countershaft Retainer Bolts............ 20 15
Drain Plug.......................................... 27 20
Drive Gear Bearing Retainer Bolts. 20 15
Extension Housing Bolts................. 30 22
Fill Plug.............................................. 27 20
Pivot Bolt........................................... 27 20
Transmission Cover Bolts............... 13 — 115
LUBRICATION SPECIFICATIONS
Capacity.................................................................................................................................................................2.8L (2.96 qts.)
Type Recommended.................................................................................................Dexron III Automatic Tranmission Fluid
T2538
7B6-16 BORG-WARNER T5 MANUAL TRANSMISSION
SPECIAL TOOLS
1. J 8001 8. C T - ^ J 6 1 3 3 -0 1
2. J 8092
9. J 37357
3. J 21426
10 . 3 7 3 5 8 -1
(/?) J 3 7 3 5 8 -2
J 2 2 9 1 2 -0 1
11. J 37359
5. J 2 3 0 6 2 -1 4
12
CZ3) J 37360
6. J 25234
13. J 37372
14. J 37375
7. J 34162 —A
15. J 8433
SECTION 7B7
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................7B7- 2
General Service Information.............................................................................................................................. 7B7- 2
Disassembly............................................................................................................................................................... 7B7- 2
Transmission Disassembly..................................................................................................................................7B7- 2
Mainshaft Disassembly........................................................................................................................................ 7B7- 6
Synchronizer Disassembly..................................................................................................................................7B7- 7
Reverse Idler Gear Disassembly....................................................................................................................... 7B7- 7
Front Housing Disassembly............................................................................................................................... 7B7- 8
Rear Housing Disassembly................................................................................................................................ 7B7- 9
Cleaning and Inspection......................................................................................................................................... 7B7-11
Mainshaft and Synchronizers............................................................................................................................. 7B7-11
Countershaft........................................................................................................................................................... 7B7-12
Reverse Idler G ear................................................................................................................................................7B7-12
Front and Rear Housings....................................................................................................................................7B7-12
Shift Shaft/Rail and Fork assemblies.............................................................................................................. 7B7-12
Shift Lever Housing............................................................................................................................................. 7B7-13
Assembly.....................................................................................................................................................................7B7-13
Input Shaft Bearing Retainer Assembly.......................................................................................................... 7B7-13
Rear Housing Assembly......................................................................................................................................7B7-14
Front Housing Assembly.....................................................................................................................................7B7-14
Reverse Idler Gear Assembly............................................................................................................................ 7B7-15
Synchronizer Assembly.......................................................................................................................................7B7-15
Mainshaft Assembly............................................................................................................................................. 7B7-15
Transmission Assembly.......................................................................................................................................7B7-17
Specifications............................................................................................................................................................ 7B7-21
Fastener Tightening Specifications...................................................................................................................7B7-21
Lubrication Specifications...................................................................................................................................7B7-21
Special Tools............................................................................................................................................................. 7B7-22
7B7-2 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
GENERAL DESCRIPTION
The New Venture Gear 3500 transmission is a
5-speed unit that is synchronized in all forward gears.
GENERAL SERVICE
The transmission has a two-piece aluminum housing INFORMATION
containing the front input shaft, rear output shaft, main
shaft gears, countershaft, reverse idler gear, shift forks,
Lubricant
and shift shaft components. The lubricant may appear to be very dark in color.
Two different versions of the 3500 transmission are This is a normal condition.
used and can be identified by the RPO code or the
Cleaning
model of truck from which it was removed. The MG5
transmission is used in the C/K truck line and M50 Thoroughly clean the exterior of the transmission.
version is used in S/T vehicles.
DISASSEMBLY
TRANSMISSION DISASSEMBLY J 36515 Assembly Pallet
J 36515-15 Mainshaft Adapter
Disassemble (Figures 1 through 16) J 36515-16 Countershaft Adapter
❖ J 24420-B Gear Puller (2WD models only)
Tool Required: J 21427-01 Speedometer Gear Puller Adapter
J 3289-20 Base Holding Fixture (2WD models only)
J 8763-02 Holding Fixture C-Clamp J 26941 Output Shaft Oil Seal Remover (2WD
J 8763-21 Balance Bracket for C-Clamp only)
J 36824 Transmission Adapters 1. Idler shaft support bolts and bottom two bolts (fig
J 36509 Detent Sprint Plug Remover ure 5).
J 23907 Slide Hammer • J 8763-21 onto J 8763-02 (figure 6).
J 36825 4WD Output Shaft Oil Seal Remover • J 36824 onto the transmission case.
(4WD models only) • J 8763-02 onto J 36824.
1. FORK, THIRD AND FOURTH SHIFT 25. SENSOR ASSEMBLY, VEHICLE SPEED
2. BUSHING, SHIFT SHAFT B L O C K -O U T 26. SWITCH ASSEMBLY, B A C K -U P LAMP
3. LEVER, SHIFT SHAFT 27. TUBE ASSEMBLY, OIL DELIVERY
4. PLUNGER, DETENT 28. BUSHING, SHIFT SHAFT
5. SPRING, DETENT 29. PLUG
6. FORK, FIRST AND SECOND SHIFT 30. SPRING, DETENT
7. PIN, ROLL 31. PLUNGER, DETENT
8. FORK, FIFTH AND REVERSE SHIFT 32. BUSHING, DETENT PLUNGER
9. SOCKET, SHIFT SHAFT 33. PLUG, OIL DRAIN
10. PIN, ROLL 34. HOUSING, FRONT
11. SHAFT, SHIFT 35. PIVOT ASSEMBLY, CLUTCH FORK
12. HOUSING ASSEMBLY, SHIFT LEVER 36. PLUG, OIL FILL
13. BOOT 37. BUSHING, SHIFT SHAFT
14. LEVER, TRANSMISSION SHIFT 38. PIN, SHAFT B L O C K -O U T BUSHING
15. BOLT, SHIFT LEVER HOUSING 39. VENT
16. PLATE ASSEMBLY, ISOLATOR 40. HOSE, VENT
17. HOUSING, REAR (4WD) 41. VENT
18. SEAL, OUTPUT SHAFT OIL (4WD) 42. RING, INPUT SHAFT BUSHING SNAP
19. SEAL, SLIP YOKE OIL (4WD) 43. BEARING, INPUT SHAFT
20. BUSHING, REAR EXTENSION (2WD) 44. RING, SNAP
21. PIN, DOWEL 45. BOLT, INPUT SHAFT BEARING RETAINER
22. BOLT, VEHICLE SPEED SENSOR 46. RETAINER, INPUT SHAFT BEARING
23. SENSOR, VEHICLE SPEED 47. SEAL, INPUT SHAFT BEARING RETAINER OIL
24. SEAL, VEHICLE SPEED SENSOR O -R IN G
2. Backup lamp switch assembly (figure 7). 15. Idler shaft support.
3. Shift shaft block-out bushing pin. • Snap out.
4. Bolt and electronic speed sensor assembly (2WD • Be careful not to loose shift lever detent plunger
models only). and spring.
5. Detent plug using J 36509 and J 23907, spring,
and plunger (figure 7). 16. Move all shift forks forward to engage fourth, sec
6. Output shaft oil seal using J 36825 and J 23907 ond, and reverse gears.
(figure 8) (4WD models only). 17. Roll pin (figure 1).
• Use J 36825 by screwing into one of the three
Important
perforated holes in the seal (4WD models only).
7. Position transmission vertically.
A. Rotate shift finger down.
8. Six bolts and input shaft bearing retainer assembly
B. Support the shift shaft end while driving out
(figure 9).
lever roll pin.
A. Tap clutch release bearing pilot with a rubber C. Allow roll pin to clear second gear.
mallet.
18. Place all gears in neutral. Then engage fifth gear.
9. Snap ring.
19. Push shift shaft all the way into the housing or.
10. Position transmission horizontally.
20. Shift shaft socket assembly roll pin (figure 1).
11. Front housing to rear housing bolts (figure 10).
12. Drive dowels into front housing. • Rotate input shaft until gap in the fifth/reverse
13. Front housing. synchronizer hub is directly under the roll pin.
14. Countershaft bearing. • Supprot shift shaft end.
7B7-4 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
• Drive shift socket pin down using a 5-mm housing from assembly (figure 12).
(3/16-inch) punch. 29. Output shaft bearing retainer (2WD models only)
• Pin will fall into the case. (figure 13).
30. Shift forks (figure 14).
NOTICE: E xcessive force will “p e e n ” the shift 31. Reverse idler gear.
shaft and damage the rear housing shift shaft 32. Countershaft.
bearing causing increased sh ift effort. 33. Countershaft bearing.
34. Speed sensor rotor using J 2 1 4 2 7 -0 1 and
J 24420-B (2WD models only) (figure 15).
21. Shift shaft, shift shaft socket assembly, biasing
• Do NOT reuse rotor after romoval.
spring, lever, and shift shaft block out bushing.
22. Rotate third-fourth shift fork counterclockwise and 35. Snap ring (2WD models only) (figure 16).
remove. 36. Bearing assembly, output shaft (2WD models
23. Loosen, but do not remove, 3 bolts on the rear of only)(figure 16).
case (2WD only). 37. Mainshaft assembly.
24. Install J 36515-15 and J 36515-16 onto the input
and countershaft. Install J 36515 to the transmis Important
sion assembly (figure 11).
25. J 8763-02 and J 36824 from the housing. • Leave the synchronizer ring on the third-fourth
26. Bolts from the rear housing (2WD only). synchronizer assembly to prevent the synchro
27. Output shaft bearing snap ring (4WD only). nizer detent balls from popping out.
28. Tap housing with a rubber mallet and remove rear 38. Input shaft gear and pilot bearing.
NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION 7B7-5
J 36824
J 8 76 3-0 2 J 3 28 9-2 0
Figure 5— Removing Bolts for Special Tools Figure 6— Holding Fixture Installed
7B7-6 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
Figure 8—Removing 4WD Oil Seal Figure 10—Removing the Front Housing
J 36515-15 J 36515-16
J 36515
Figure 12—Rear Housing Figure 14—Gears and Shift Forks
13. Fifth speed gear bearing (figure 20).
14. Snap ring (figure 21). Important
15. Reverse speed gear assembly and fifth-reverse
synchronizer assembly using J 22912-01 and • Do not mix parts.
hydraulic press (figure 21).
A. Scribe on hub and sleeve so the parts can be REVERSE IDLER GEAR
reinstalled in the same position.
B. Leave the synchronizer ring on the fifth-reverse DISASSEMBLY
synchronizer assembly to prevent the synchro
nizer detent balls from popping out.
16. Reverse speed gear bearing assembly (figure 21). * Disassemble (Figure 23)
17. Drag seal from the mainshaft.
18. Drag seal from the reverse speed gear. 1. Snap ring.
2. Thrust washer.
SYNCHRONIZER DISASSEMBLY 3. Locating ball.
4. Reverse gear.
* Disassemble (Figure 22) 5. Bearing assembly.
6. Thrust washer.
1. Place first-second, third-fourth, and fifth speed syn 7. Locating ball.
chronizers in separate shop towels. Wrap assem 8. Wave washer.
blies and press against inner hub. 9. Snap ring.
7B7-8 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
Figure 19— Removing Second Gear Components Figure 21—Removing Reverse Gear Components
• Wear.
• Scuffed.
FRONT AND REAR HOUSINGS
• Nicked.
• Burred or broken teeth. L* Inspect
7. Speed gear clutching cones for:
1. Bearing race bore, for wear, scratches, or grooves:
• Synchronizer ring metal transfer.
if counter shaft bearing race bore is worn or dam
8. All gear teeth for:
aged the rear housing MUST be replaced.
• Excess wear.
2. Bushings, for scores, burrs, roundness, or evidence
— The black phosphate coating will develop of overheating.
wear patterns. This is a normal condition.
9. Bearings and bearing surfaces for: Important
• Nicks.
• Burrs. • Output shaft bushing cannot be serviced.
• Bent cages. Replace the rear housing if the bushing is worn
• Wear. or damaged (2WD models only).
10. Lubricate all bearings and check for rough rotation.
3. Case for cracks, threaded opening for damaged
• If scuffed, nicked, burred, scoring, or synchro
threads, mounting faces for nicks, burrs, or
nizer ring metal transfer conditions cannot be
scratches; if case is cracked, it must be replaced.
removed with a soft stone or crocus cloth,
4. Machined mating surfaces for flatness. Check with
replace the component and inspect mating
a straight edge.
parts.
• Lubricate all components as assembly progres
Important
ses. Use lubricant Synchromesh Transmission
Fluid GM P/N 12345349 or equivalent.
• If scratches, grooves, or scoring cannot be
removed with a soft stone or crocus cloth,
COUNTERSHAFT replace the component.
• Clean up damaged threads with correct size
Clean
tap.
All parts in a suitable solvent and air dry.
SHIFT SHAFT AND FORK
1* Inspect ASSEMBLIES
1. Shaft for cracks. Replace if these conditions exist. Clean (Figure 31)
2. Gear teeth for scuffed, nicked, burred, broken
teeth, or high spots (a small shiny spot on the gear All parts in a suitable solvent and air dry.
teeth mating surface) that could cause gear noise.
3. Bearings for roughness of rotation, burred, or pitted L* Inspect
condition. Replace if these conditions exist.
4. Bearing races for scoring, wear, or overheating. • Shift fork and inserts are serviced as an assembly
• If scuffed, nicked, or burred conditions cannot only.
be removed with a soft stone or crocus cloth, 1. Shaft for wear or scoring.
replace the component.
• Fifth gear CANNOT be pressed off the counter
shaft assembly. Replace as an assembly only.
Inspect
Oil Seal
2. Forks for wear, scoring, or distortion. The edges
will turn black in color. This is a normal condition. I? Inspect (Figure 33)
3. Shift lever and blockout bushing for wear.
4. Pins for wear or distortion. • Isolator plate for wear or distortion with a straight
5. Shift shaft socket assembly components for wear edge.
or distortion. • The parts that compose the shift lever housing
assembly are serviceable as an assembly only.
Important
Replace the assembly for any shift lever rat
W ear or distortion requires replacement of tle/buzz.
assembly and close inspection of mating parts. • Boot for cracks, tears, or distortion. Replace the
boot if any of these conditions exist.
SHIFT LEVER HOUSING • Machined mating surface for flatness. Check with a
straight edge.
ASSEMBLY
j Clean (Figure 32)
ASSEMBLY
2. Input shaft bearing retainer oil seal.
INPUT SHAFT BEARING
A. Heat oil seal with J 25070 for minimum of 3
RETAINER ASSEMBLY minutes.
B. Hold the clutch release bearing pilot with a heat
Remove or Disconnect (Figure 33) resisting glove or equivalent. Remove the seal
with a slide hammer.
Tools Required:
3. Gasket material from the retainer using liquid gas
J 29369-2 Input Shaft Bearing Retainer Oil Seal
ket remover.
Remover
J 23907 Slide Hammer
J 25070 Heat Gun L9 Inspect
J 36504 Input Shaft Bearing Oil Seal Installer
1. Clutch release bearing pilot for scoring, wear, or
Seal Replacement cracks, especially at the flange.
1. Rubber seal lip with pliers. 2. Retainer for wear or damage.
• Exposing the metal lip:
+«- Install or Connect (Figure 34)
A. Install J 29369-2 below metal lip of seal.
B. Expand to finger tight.
C. Turn five additional turns. 1. NEW oil seal using J 36504.
D. Install J 23907 into J 29369-2. • Fill between the seal lip with chassis grease.
7B7-14 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
Tools Required:
J 36190 Drive Handle
J 36503 Output Shaft Oil Seal Installer
J 36506 Fifth and Reverse Detent Bushing
Remover/Installer
1. Rear housing shift shaft bearing using J 36506 and J 36503
J 36190 (figure 35).
A. Install bearing into bore so that the writing on
bearing lip faces down.
B. Install flush.
Tighten
Tools Required:
J 36183 Input Shaft Press Tube with Cap
Oil Seal J 36184 Adapter Press Tube Reducer
NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION 7B7-15
6. Oil fill plug and oil drain plug using J 36511 (figure
27).
• Apply pipe sealant with Teflon ™ GM P/N
1052080 or equivalent to the threads.
Tighten
MAINSHAFT ASSEMBLY
* Assemble (Figures 41 through 45)
Tools Required:
Hydraulic Press
J 36183 Input Shaft Press Tube with Cap
J 36184 Adapter Press Tube Reducer
J 39924-1 Reverse Drag Seal Installer
J 39924-2 Fifth Gear Drag Seal Installer
7B7-16 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
Important
Figure 44— Installing First Gear Components Figure 46—Installing Third Gear Components
11. First-second synchronizer assembly with both syn 16. Bearing assembly and third speed gear (figure 46).
chronizer rings using J 36183 and J 36184 and a 17. When pressing the third-fourth synchronizer
hydraulic press (figure 44). assembly:
• Check scribe marks for correct positions.
A. Manually align and engage splines.
Important B. Start press operation, STOP before tangs
engage.
• The groove on the outside of the sleeve MUST C. Lift and rotate gear, to engage synchronizer
GO TOWARDS THE SECOND SPEED GEAR ring.
to prevent gear clash during first and second D. Continue to press until seated.
gear shifts. The teeth of the sleeve have differ E. Be sure all shavings are removed.
ent angles.
18. Third-fourth synchronizer assembly with both syn
12. Snap ring (figure 44).
chronizer rings using J 36183 and J 36184 and a
13. Synchronizer cone, blocker ring, reaction cone and
hydraulic press (figure 46).
interim ring (figure 45).
19. NEW snap ring.
14. Bearing assembly and second speed gear (figure
45).
• Make sure bearing cage is together. TRANSMISSION ASSEMBLY
15. Spacers and collar.
• Install spacers with the locating dots facing up. Assemble (Figures 6, 9, 10, 11, 12, 14, 16, 47
through 53)
Tool Required:
J 25070 Heat Gun (2WD models only)
J 36515-10 Retainer Alignment Cables (2WD
models only)
J 36502 4WD Oil Seal Installer
J 36502-2A 4WD Seal Protector
J 36515 Assembly Pallet
J 36515-16 Countershaft Adapter
J 36515-15 Mainshaft Adapter
J 3289-20 Base Holding Fixture
J 8763-02 Holding Fixture C-Clamp
J 8763-21 Balance Bracket for C-Clamp
J 6133-01 Speedometer Rotor Installer (2WD
models only)
J 36824 Transmission Holding Fixture Adapters
NOTICE: For ste p s 13, 18, 30, 36, 39, 40, 41,
Figure 45—Installing Second Gear Components 42, and 44, refer to “N otice” on page 7B1-1.
7B7-18 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
10. Bearing (2WD models only)(figure 49). D. Press each roller towards the race to secure
A. Install in bearing race of the housing, with the them for easier assembly.
smaller diameter of the bearing cage into the 14. Rear housing assembly (4WD models only) (figure
bearing race. 12 ).
B. Retain with TRANSJEL ™ J 36850 or equiva A. Make sure the reverse idler shaft is lined up
lent. with the hole in the case.
B. Rotate back and forth while pulling down.
Important
Important
• Press each roller towards the race to secure
them for easier assembly. • Bring the housing straight down. If resistance is
11 Rear housing assembly (2WD models only)(figure felt at about 7 mm (1/4 in.), then the rollers are
49). cocked. Repeat above procedures to install. Do
A. Make sure the reverse idler shaft is lined up not force the housing down.
with the hole in the case. — Install seal protector J 36502-2A onto output
B. Rotate back and fourth while pulling down. shaft.
C. Pull up on J 36515-10 while installing rear 15. Output shaft oil seal using J 36502 (figure 51)
housing. (4WD models only).
A. Fill between the seal lip with chassis grease.
Important B. Remove seal protector J 36502-2A.
Figure 51—Installing 4WD Rear Housing Oil Seal Figure 52—Installing Reverse Idler Support
7B7-20 NEW VENTURE GEAR N V 3500 MANUAL TRANSMISSION
£ Tighten Tighten
• Shift tower bolts to 8.5 N m (75 lbs. in.). • Bolts to 8.5 N-m (75 lbs. in.).
29. Countershaft bearing to countershaft race (figure
35. Shift shaft detent plunger, shift shaft detent spring,
10). and plug using brass drift (figure 53).
Important • Apply pipe sealant with Teflon ™ GM P/N
1052080 or equivalent to the plug.
A. Install smaller diameter of bearing cage into the 36. Install new O-ring onto electronic speed sensor
bearing race. assembly (2WD models only).
B. Press each roller into cage and retain with • Coat the O-ring with a thin film of transmission
TRANSJEL ™ J 36850 or equivalent. fluid.
C. Apply TRANSJEL ™ J 36850 or equivalent to
37. Electronic speed sensor assembly and bolt (2WD
bearing race on input shaft.
models only)(figure 53).
30. Front housing (figure 10).
Important
• Bolt to 9 N m (80 lbs. in.).
Bring the housing straight down. If resistance is
felt at about 7 mm (1/4 in.), then the rollers (35) 38. Backup lamp switch assembly (figure 53).
are cocked. Repeat step 30. Do not force down • Apply pipe sealant with Teflon ™ GM P/N
the housing. 1052080 or equivalent to the threads.
NEW VENTURE GEAR N V 3500 MANUAL TRANSMISSION 7B7-21
Tighten
• Switch to 9 N-m (80 lbs. in.). • Anchor bolt to 25 N-m (18 lbs. ft.).
39. Remove J 8763-02 and J 36824 (figure 6). 41. Fill transmission with Synchromesh Transmission
Fluid or the equivalent.
$ Tighten 42. Oil fill plug.
Tighten
• Bolts (figure 5) to 35 N-m (26 lbs. ft.). &
40. Blockout bushing anchor bolt.
Oil fill plug to 60 N-m (44 lbs. ft.).
SPECIFICATIONS
FASTENER TIG H TEN IN G SPECIFICATIONS
N-m Lbs. Ft. Lbs. In.
Backup Lamp Switch............................................................................................. 9 — 80
Blockout Bushing Anchor Bolt....................................................................................... 25 18 —
Front to Rear Housing Bolts................................................................................. ......... 35 26 —
Idler Shaft Support Bolt........................................................................................ ......... 22 16 —
Input Shaft Bearing Retainer Bolts........................................................ ............. ......... 8.5 — 75
Oil Drain Plug......................................................................................................... ......... 60 44 —
Oil Fill Plug....................................................................................................................... 60 44 —
Output Shaft Bearing Retainer Bolts............................................................................ 22 16 —
Shift Tower Bolts.................................................................................................... ......... 10 — 89
Speed Sensor Bolt................................................................................... ............. 9 — 80
LUBRICATION SPECIFICATIONS
Capacity.................................................................................................................................................................1.98L (2.0 qts.)
Type Recommended............................................................................................................Synchromesh Transmission Fluid
T3157
7B7-22 NEW VENTURE GEAR N V3500 MANUAL TRANSMISSION
SPECIAL TOOLS
7. 13.
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
14.
J 6 1 2 5 -1 8 J 23907 J 36184
15.
J 6 1 3 3 -0 1 J 24420- B J 36190
4. 10 . 16.
CSH
J 8092
J 25070 J 36502
5. 11 . 17.
J 2 1 4 2 7 -0 1 J 2 9 3 6 9 -2 J 36504
19.
1. HOLDING FIXTURE
2. SLIDE HAMMER WITH ADAPTER
3. BEARING RACE INSTALLER
4. UNIVERSAL DRIVER HANDLE J 36506
5. SPEEDOMETER GEAR PULLER
14. ADAPTER PRESS TUBE REDUCER
6. SPEEDOMETER GEAR PULLER ADAPTER
15. UNIVERSAL DRIVER HANDLE
7. SEPARATOR PLATE OF EQUIVALENT
16. 4WD OUTPUT SHAFT OIL SEAL
8. SLIDE HAMMER WITH PILOT BEARING PULLER
INSTALLER AND SEAL PROTECTOR
9. GEAR PULLER 17. 2WD OUTPUT SHAFT OIL SEAL INSTALLER
10. HEAT GUN OR EQUIVALENT
18. INPUT SHAFT BEARING RETAINER
11. 2WD OUTPUT SHAFT OIL SEAL REMOVER
12. INPUT SHAFT BEARING RETAINER OIL SEAL INSTALLER
OIL SEAL REMOVER 19. 5TH AND REVERSE DETENT BUSHING
13. INPUT SHAFT REMOVER/INSTALLER REMOVER/INSTALLER
PRESS TUBE CAP 3707r5185
NEW VENTURE GEAR N V 3500 MANUAL TRANSMISSION 7B7-23
SPECIAL TOOLS
J 36507
J 3 6 5 1 5 -1 0
21.
J 3 6 5 1 5 -1 5
J 3 6 5 1 5 -1 6
NOTES
. 4
-v •
1*. ’ • ,■ .
'■ .. -'v"*:
'■ - ' -2t, ■■'- -
■
, ‘v -
-r;
•, > -'•*.*;» . f . ,
. . .. „
t- ■ ■ . *. .
-
:s ■ ftme
NEW VENTURE GEAR 4500 MANUAL TRANSMISSION 7B8-1
SECTION 7B8
CONTENTS
SUBJECT PAGE
Unit Disassembly......................................................................................................................................................7B8- 1
Disassembly and Assembly of Sub-Assemblies..............................................................................................7B8- 4
Main Drive Gear.....................................................................................................................................................7B8- 4
Mainshaft..................................................................................................................................................................7B8- 4
Countershaft........................................................................................................................................................... 7B8- 7
Rear Oil Retainer Extension Housing.............................................................................................................. 7B8- 8
Main Drive Gear Bearing Retainer....................................................................................................................7B8- 9
Seal Replacement............................................................................................................................................. 7B8- 9
Shift Cover.............................................................................................................................................................. 7B8- 9
Unit Assem bly........................................................................................................................................................... 7B8-10
Specifications............................................................................................................................................................ 7B8-12
Fastener Tightening Specifications.................................................................................................................. 7B8-12
Lubrication Specifications............................. ..................................................................................................... 7B8-12
Special Tools............................................................................................................................................................. 7B8-13
UNIT DISASSEMBLY
+-► Remove or Disconnect (Figures 1 through 12)
Tools Required:
J 23642-01 Transmission Holding Fixture
J 24462 Transmission Adapter Plate
J 38805 Output Shaft Nut Socket (4WD models
only)
1. Shift tower to the shift cover bolts.
2. Shift tower from the shift cover (figure 1).
3. Shift tower isolator plate from the shift cover (figure VjN
1).
4. Shift cover to the transmission case bolts. i
5. Shift cover from the transmission case (figure 2). £ cL
• Separate the shift cover from the transmission s\ 1 /
case by inserting screwdrivers in the slots pro
I i
vided. Do not attempt to pry apart on the mating
surfaces or damage to the surfaces may result.
6. Mainshaft nut, washer, and spline sea! (2WD mod
&
els).
\
7. Yoke assembly (2WD models).
8. Rear oil retainer bolts.
Figure 1—Shift Tower
7B8-2 NEW VENTURE GEAR 4500 MANUAL TRANSMISSION
Removal
Figure 4— Mainshaft Nut Removal (4WD Models) Figure 7— Main Drive Gear
NEW VENTURE GEAR 4500 MANUAL TRANSMISSION 7B8-3
Figure 8—Fifth Gear Components Figure 11—Reverse idler Gear Shaft Removal
16. Fifth gear clutch gear snap ring. 22. Mainshaft assembly (figure 10).
17. Fifth gear assembly from the countershaft (figure • Lift the mainshaft assembly by the nose through
8). the front. It may be necessary to wiggle and
twist the mainshaft assembly to remove the
• Slide overdrive fork as far rearward as possible second speed gear from the countershaft.
while working the overdrive gear assembly rear 23. Countershaft bearing retaining plate bolts.
ward. 24. Countershaft bearing retainer plate and shim(s).
• If unable to remove overdrive gear assembly, 25. Countershaft rear bearing cup.
remove overdrive clutch gear, synchronizer ring, 26. Reverse idler gear shaft (figure 11).
spacer, and overdrive gear bearings to lower • Using a punch, push the reverse idler shaft out
and remove overdrive gear. from inside the transmission case.
• Do not let the synchronizer come apart. 27. Reverse idler gear, washers, bearings, and spacer.
18. Countershaft thrust washer and pin. 28. Countershaft rear bearing (figure 12).
19. Mainshaft fifth gear and vehicle speed sensor rotor • Make sure the bearing puller is attached to the
bearing inner race.
(2WD only) from the mainshaft (figure 9).
20. Mainshaft rear bearing retaining plate bolts. 29. Countershaft assembly from the transmission case.
30. Countershaft bearing cap.
21. Mainshaft bearing retainer plate, shim(s), and
31. Countershaft front bearing cup.
mainshaft rear bearing cup.
32. Fifth gear shift lever retaining pin.
• Move synchronizer sleeves into neutral position. 33. Fifth gear shift lever shaft.
• Raise fifth gear shift lever up out of the way • Push shaft outward from inside of case.
and hold with a rubber band. 34. Fifth gear shift lever.
I? Inspect
Tool Required:
J 22828 Main Drive Gear Bearing Installer
1. Bearing using J 22828 (figure 13).
2. Pilot bearing.
MAINSHAFT
* Disassemble (Figures 14 through 30)
Figure 14— Main Drive Gear Thrust Bearing Figure 16—Third Gear Bearings and Spacer
Figure 15— 3-4 Synchronizer and Third Gear Figure 17—Second Gear Thrust Washer, Retaining
Pin, and Snap Ring
12. Second gear synchronizer ring snap ring (figure 20).
13. Second gear synchronizer rings (figure 21). Jp Inspect
14. 1-2 synchronizer sleeve and hub snap ring (figure
22).
1. Gears for cracks, chipped gear teeth, and other
15. 1-2 synchronizer assembly (figure 23).
damage that could cause gear noise.
• Do not let the synchronizer assembly come
2. Thrust washers for damage and wear.
apart during disassembly of transmission.
3. Synchronizer sleeves for a sliding fit on the syn
16. First gear synchronizer ring snap ring (figure 24).
chronizer hubs.
17. First gear synchronizer rings (figure 25).
18. First gear clutch gear snap ring. • The hubs have to be a snug fit on the main
19. First gear clutch gear. shaft splines.
• Turn the mainshaft over.
20. Rear mainshaft bearing (figure 26). 4. Synchronizer springs and keys for looseness and
21. Reverse gear thrust washer (figure 27). damage.
22. Reverse gear and synchronizer assembly from the 5. All gear teeth for excess wear.
mainshaft (figure 28). 6. Bearings and bearing surfaces for nicks, burrs and
23. Reverse gear bearing and spacer (figure 29). wear.
24. Reverse gear clutch gear snap ring. 7. Lubricate all roller bearings with Castrol Syntorq LT
25. Reverse gear synchronizer ring and clutch gear. transmission fluid and check for rough rotation.
26. First gear and bearing (figure 30).
7B8-6 NEW VENTURE GEAR 4500 MANUAL TRANSMISSION
Figure 26— Rear Mainshaft Bearing Removal Figure 28— Reverse Gear
Figure 27—Reverse Gear Thrust Washer Figure 29— Reverse Gear Bearing and Spacer
Figure 30— First Gear and First Gear Bearing Figure 32—Rear Oil Retainer Seal Installation
38801
Figure 31— Rear Oil Retainer Seal Installation Figure 33—Main Drive Gear Retainer Seal
Installation
MAIN DRIVE GEAR BEARING
-►*- Install or Connect (Figure 33)
RETAINER
Tool Required:
Seal Replacement J 38801 Main Drive Gear Retainer Seal
Installer
Remove or Disconnect
1. Seal into the main drive gear bearing retainer using
J 38801 (figure 33).
1. Seal from the main drive gear bearing retainer.
• The lip of the seal goes toward the installing
• Pry the seal out with a small pry bar or equiva tool.
lent.
SHIFT COVER
L* Inspect
Important
• Retainer nose for scoring, wear, or cracks, espe
cially at the flange. Do not disassemble the shift cover. Individual compo
• Retainer for wear and damage. nents of the shift cover are not serviced. If the shift
cover is damaged or worn, it must be replaced as a
complete assembly.
7B8-10 NEW VENTURE GEAR 4500 MANUAL TRANSMISSION
UNIT ASSEMBLY
+ 4- Install or Connect (Figures 1, 3, 4, 6, 7, 10, 34 lj|] Measure
through 39)
• Countershaft end play (figure 36).
Tools Required:
J 22828 Countershaft Bearing and Input Shaft A. Set the dial indicator up on the end of the coun
Bearing Installer tershaft.
J 23642-01 Transmission Holding Fixture B. Use screwdriver or the equivalent to lift counter
J 24462 Transmission Adapter Plate shaft up and down to measure end play.
J 38805 Output Shaft Nut Socket (4WD Models) C. Countershaft end play should be 0.05-0.15 mm
J 38856 Countershaft Bearing Cone and (0.002-0.006 in.).Adjust by adding or removing
Retainer Installer shim(s) under bearing retainer plate.
J 39314 Vibration Damper Installer D. Remove bolts and apply Loctite® Dri-Loc 201
(4WD Models) or equivalent to the bolts and retorque.
1. Fifth gear shift lever. 12. Countershaft bearing cap using J 38856 (figure
2. Fifth gear shift lever shaft. 37).
3. Fifth gear shift lever retaining pin.
• Hold fifth shift lever back out of the way using a • Ensure outer lip is hit evenly until flush with
rubber band (figure 34). case.
• Ensure the notches that retain the fifth gear fork
are to the outside of the case.
4. Countershaft front bearing cup using J 38856 (fig
ure 34).
5. Countershaft assembly into the transmission case.
6. Countershaft rear bearing using J 22828 (figure
35).
• Raise and support the countershaft assembly
by positioning a wood block between the front
of the countershaft and the transmission case.
7. Reverse idler gear, bearings, spacer, and washers
into the transmission case.
8. Reverse idler gear shaft.
9. Countershaft rear bearing cup.
10. Countershaft shim(s) and bearing retainer plate.
11. Countershaft bearing retainer plate bolts.
Tighten
J 38856
Tighten
* Measure
& Tighten
$ Tighten
HI Tighten HI Tighten
• Yoke nut to 441 N-m (325 lbs. ft.). • Shift cover bolts to 23 N-m (17 lbs. ft.).
30. Fill transmission with proper amount of lubricant. 33. Shift tower isolator plate to the shift cover (figure
1).
Important • Apply GM P/N 1052942 or the equivalent to the
shift cover side of the isolator plate only.
Use of any lubricant other than Castrol Syntorq 34. Shift tower to the isolator plate (figure 1).
LT transmission fluid or equivalent will result in 35. Shift tower to shift cover bolts.
transmission failure.
31. Shift cover to the transmission case. a Tighten
• Apply GM P/N 1052942 or the equivalent to the
Shift tower bolts to 6.0 N-m (53 lbs. in).
mating surfaces.
32. Shift cover to the transmission case bolts.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Item N-m Lbs. Ft.
Countershaft Retainer Plate-to-Case Bolt........................................................................................... 35 26
Main Drive Gear Retainer-to-Case Bolt...................................................................................... ........ 31 23
Mainshaft Retainer Plate-to-Case Bolt........................................................................................ ........ 35 26
Rear Oil Retainer-to-Case Bolt..................................................................................................... ........ 54 40
Shift Lever Cover-to-Case Bolts................................................................................................... ........ 23 17
Vibration Damper Mounting Nut (4WD Models)........................................................................ 441 325
Yoke Assembly Mounting Nut (2WD Models)............................................................................ ........ 441 325
LUBRICATION SPECIFICATIONS
Capacity................................................................................................................................................................. 3.78L (8 Pints)
Type Recommended.................................................................................................. Castrol Syntorq LT Transmission Fluid
T2860
NEW VENTURE GEAR 4500 MANUAL TRANSMISSION 7B8-13
SPECIAL TOOLS
J 22828 J 38807
J 38856
J 22834
J 38801 J 39314
4. J 38805
v ja e r
'
SECTION 7D
TRANSFER CASE
CONTENTS
SUBJECT PAGE
New Process 233 Transfer Case............................................................................................................................. 7D1-1
New Process 241 Transfer Case............................................................................................................................. 7D2-1
New Process 231 Transfer Case............................................................................................................................. 7D3-1
Borg-Warner 4401 Transfer Case............................................................................................................................ 7D4-1
Borg-Warner 4472 Transfer Case............................................................................................................................ 7D5-1
Borg-Warner 4470 Transfer Case............................................................................................................................ 7D6-1
SECTION 7D1
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................7D1- 2
Model 2 3 3 ................................................................................................................................................................7D1- 2
Identification....................................................................................................................................................... 7D1- 2
Power Flow ......................................................................................................................................................... 7D1- 3
Disassembly................................................................................................................................................................7D1- 3
External Components........................................................................................................................................... 7D1- 3
Mainshaft Extension and Oil Pump Housing.................................................................................................7D1- 3
Internal Components............................................................................................................................................ 7D1- 5
Cleaning and Inspection......................................................................................................................................... 7D1-10
Assembly..................................................................................................................................................................... 7D1-10
Bearing and Seal Replacement......................................................................................................................... 7D1-10
Internal Components............................................................................................................................................ 7D1-11
External Components........................................................................................................................................... 7D1-12
Specifications............................................................................................................................................................ 7D1-12
Fastener Tightening Specifications...................................................................................................................7D1-12
Lubrication Specifications...................................................................................................................................7D1-12
Special Tools............................................................................................................................................................. 7D1-13
7D1-2 NEW PROCESS 233 TRANSFER CASE
GENERAL DESCRIPTION
MODEL 233 electronic shift mechanism, and a planetary gear
assembly. The drive sprockets are connected and oper
The Model 233 is an electronic shift transfer case
ated by the drive chain. The planetary gear assembly
with three modes of operation: two-wheel drive range,
consists of a 4-pinion planetary carrier and an annulus
four-wheel drive high range and four-wheel drive low
gear that provide the four-wheel drive low range when
range. Gear reduction for low range is provided by a
engaged. The reduction ratio is 2.72:1 in this range.
planetary gear set. The floor-mounted shifter has been
The electronic shift mechanism is controlled by an elec
eliminated on vehicles equipped with this transfer case.
tronic shift encoder motor and a transfer case control
A switch located on the upper right side of the instru
ment panel is used to select the operating range. Indi module. The electronic shift encoder motor is mounted
cator lamps on the switch show the current mode of on the front half of the transfer case and the transfer
operation. case control module is mounted in the passanger com
partment.
When four-wheel drive has been selected, the
four-wheel drive indicator lamp on the switch is
IDENTIFICATION
designed to come on when the front axle has engaged.
The lamp will blink while the front axle is engaging. This An identification tag is attached to the rear half of the
is normal. transfer case (figure 1). This tag provides the transfer
The 233 has a two-piece aluminum case containing case model number, low range gear reduction ratio, and
front and rear output shafts, two drive sprockets, an assembly number. The information on this tag is neces
sary when servicing this transfer case. If the tag is as in 2HI range. However, in the 4HI position, the mode
removed or becomes dislodged during service opera synchronizer sleeve is shifted into engagement with the
tions, be sure to keep the tag with the unit. clutch teeth of the drive sprocket. This locks the drive
sprocket to the mainshaft through the synchronizer.
POWER FLOW
Torque is transmitted through the drive sprocket to the
In all drive range positions input torque is transmitted
driven sprocket by the connecting drive chain. The
to the transfer case gear train through the transfer case
torque flows through the front output shaft to the front
input gear. In 2HI range, torque flows from the input
gear to the range shift hub and mainshaft. Torque flow propeller shaft and axle resulting in high range
continues through the slip yoke which is splined to the four-wheel drive.
mainshaft, and finally to the rear propeller shaft and In 4LO range, the path of torque through the transfer
axle. The mode synchronizer remains in the neutral case is exactly the same as in 4HI range but with one
position and does not lock the drive sprocket to the major difference. In 4LO range the range shift hub is
mainshaft. As a result, torque is not transferred to the shifted into engagement with the planetary carrier. This
driven sprocket. causes the input gear to rotate the planetary pinions
In 4HI range, input torque from the input gear is inside the annulus gear, causing the planetary carrier,
transmitted to the mainshaft in exactly the same fashion range shift hub, and mainshaft to rotate at a gear
reduction ratio of 2.72:1.
DISASSEMBLY
EXTERNAL COMPONENTS 3. Vacuum switch and O-ring seal (figure 4).
4. Vehicle speed sensor and O-ring seal (figure 5).
5. Detent plug, detent spring, and detent plunger (fig
| Clean (Figures 3 through 6)
ure 6).
The transfer case exterior using solvent and a stiff MAINSHAFT EXTENSION AND
brush. OIL PUMP HOUSING
I+ -H Remove or Disconnect Remove or Disconnect (Figures 7 through 13)
1. Encoder motor to the transfer case bolts (figure 3). 1. Rear extension housing bolts and the rear exten
2. Encoder motor from the transfer case (figure 3). sion housing (figure 7).
7D1-4 NEW PROCESS 233 TRANSFER CASE
• Tap the extension housing with a rubber mallet 8. Case bolts from the case halves.
to free from the sealer.
2. Rear bearing retainer snap ring from the mainshaft • Note: The two longer case bolts and washers
(figure 8). go into the doweled case holes.
3. Rear retainer housing bolts.
4. Rear retainer housing from the rear case half (fig Important
ure 9).
• Carefully pry upward under each tab on retainer • Some transfer case models have a bracket
housing. attached to them by the case half bolts. These
bolts are different from the others and must be
Important put back into the correct holes.
• Do not pry against the sealing surfaces of the 9. Rear case half and oil pump as an assembly from
rear retainer or rear case. Only pry under tabs the front case (figure 13).
on retainer housing.
• Separate the case halves by inserting screw
5. Vehicle speed sensor rotor snap ring from the
drivers into the slots cast into the case ends
mainshaft (figure 10).
and pry apart. Do not attempt to wedge the
6. Vehicle speed sensor rotor from the mainshaft (fig
ure 11). case halves apart at any point on the mating
7. Snap ring from the mainshaft (figure 12). surfaces. Damage to the case may result.
NEW PROCESS 233 TRANSFER CASE 7D1-5
Figure 8— Rear Bearing Retainer Snap Ring Figure 10—Vehicle Speed Sensor Rotor Snap Ring
Ring
Figure 16— Mode Fork Shift Spring Figure 18— Drive Chain, Mainshaft, and Driven
Sprocket
Figure 22—Sector Shaft Snap Ring Figure 25—Input Gear Snap Ring
NEW PROCESS 233 TRANSFER CASE 7D1-9
ASSEMBLY
BEARING AND SEAL 1. Needle bearings into the rear case half using
J 33832 and J 8092.
REPLACEMENT • Bearing must be flush with the boss on case
housing.
|-K-| Install or Connect (Figures 27, 31, 33 and 34)
2. Front output bearing into the front case half using
Tools Required: J 8092 and J 33833.
J 8092 Driver Handle 3. Front output bearing snap ring.
J 33833 Bearing Installer 4. Bearing into the rear retainer housing using
J 36372 Bearing Installer J 33833 and J 8092 (figure 33).
J 33843 Seal Installer 5. Bearing into the input gear using J 36372 and
J 8092.
J 33831 Seal Installer
6. Thrust washer into planetary carrier (figure 27).
• Use Dexron® III automatic transmission fluid or the 7. Input gear and thrust washer into planetary carrier
equivalent for lubricant during assembly. (figure 27).
NEW PROCESS 233 TRANSFER CASE 7D1-11
— ■ -I-
$ Tighten
EXTERNAL COMPONENTS
0 Install or Connect (Figures 3 through 6)
£ Tighten
4. Encoder motor and the encoder motor to the trans
• Detent plug to 15 N-m (11 lbs. ft.). fer case bolts (figure 3).
2. Vehicle speed sensor and O-ring to the rear retain
er housing (figure 5). & Tighten
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N-m Lbs. Ft.
Case Half Bolts............................................................................................................................... 31 23
Encoder Motor Bolts....................................................................................................................... 18 13
Fill and Drain Plugs.................................................. ..................................................................... 47 35
Input Shaft Bearing Retainer Bolts............................................................................................... 19 14
Mainshaft Extension Housing Bolts.............................................................................................. 31 23
Poppet Screw............................................................. .................................................................... 15 11
Rear Reatiner Bolts................................................................................................................. ....... 31 23
Shift Selector Lever Nut................................................................................................................. 31 23
Shift Selector Vacuum Switch....................................................................................................... 24 17
Vehicle Speed Sensor.................................................................................................................... 31 23
LUBRICATION SPECIFICATIONS
Capacity.............................................................................................................................................................. 1.18L (1.25 qts.)
Type Recommended............................................................................................Dexron® III Automatic Transmission Fluid
T2865
NEW PROCESS 233 TRANSFER CASE 7D1-13
SPECIAL TOOLS
1. SLIDE HAMMER
2. DRIVER HANDLE 8. BEARING INSTALLER
3. BEARING REMOVER 9. BEARING INSTALLER
4. BEARING REMOVER 10. SEAL INSTALLER
5. OUTPUT SHAFT BEARING REMOVER 11. EXTENSION HOUSING SEAL INSTALLER
6. ADAPTER 12. BEARING INSTALLER
7. BEARING INSTALLER 13. BEARING REMOVER
V2831
NOTES
,SI
, i .*'•< 1•
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e ■
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wcuvm
NEW PROCESS 241 TRANSFER CASE 7D2*1
SECTION 7D2
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................7D2- 1
Model 2 4 1 ............................................................................................................................................................... 7D2- 1
Identification....................................................................................................................................................... 7D2- 1
Power Flow ......................................................................................................................................................... 7D2- 1
Disassembly................................................................................................................................................................7D2- 2
External Components........................................................................................................................................... 7D2- 2
Mainshaft Extension and Rear Retainer Housing......................................................................................... 7D2- 2
Internal Components............................................................................................................................................ 7D2- 4
Cleaning and Inspection......................................................................................................................................... 7D2- 7
Assembly..................................................................................................................................................................... 7D2- 8
Bearing and Seal Replacement......................................................................................................................... 7D2- 8
Internal Components............................................................................................................................................ 7D2- 8
External Components........................................................................................................................................... 7D2- 9
Specifications............................................................................................................................................................ 7D2-10
Fastener Tightening Specifications...................................................................................................................7D2-10
Lubrication Specifications...................................................................................................................................7D2-10
Special Tools............................................................................................................................................................. 7D2-10
GENERAL DESCRIPTION
MODEL 241 IDENTIFICATION
An identification tag is attached to the rear half of the
The Model 241 transfer case is a chain-driven, transfer case. This tag provides the transfer case model
four-position unit providing four-wheel drive high and number, low range reduction ratio, and an assembly
low ranges, a two-wheel high range, and a neutral posi number. The information on this tag is necessary for
tion. The Model 241 is a part-time four-wheel drive unit. servicing this transfer case. If the tag is removed or
Torque input in four-wheel high and low ranges is undif becomes dislodged during service operations, be sure
ferentiated. The range positions are selected by a to keep the identification tag with the unit.
floor-mounted gearshift lever. POWER FLOW
The Model 241 has a two-piece aluminum case con
In all drive range positions input torque is transmitted
taining front and rear output shafts, two drive sprockets, to the transfer case gear train through the transfer case
a shift mechanism, and a planetary gear assembly. The input gear.
drive sprockets are connected and operated by the In 2HI range, torque is transmitted from the input gear
drive chain. The planetary assembly which, consists of to the range shift hub and mainshaft. Torque flow con
a six-pinion carrier and an annulus gear provides the tinues through the slip yoke which is splined to the
four-wheel drive low range when engaged. The gear mainshaft, and finally to the rear propeller shaft and
reduction ratio is 2.72:1 in this range. axle. In 2HI range, the mode synchronizer remains in
the neutral position and does not lock the drive sprock
et to the mainshaft. As a result, torque is not transferred
to the driven sprocket.
7D2-2 NEW PROCESS 241 TRANSFER CASE
In 4HI range, torque from the input gear is transmitted In the 4LO range, the path of torque through the
to the mainshaft in exactly the same fashion as in the transfer case is exactly the same as in the 4HI range
2HI range. However, in 4HI position, the mode synchro but with one major difference.
nizer sleeve is shifted into engagement with the clutch In the 4LO range, the range shift hub is shifted into
teeth of the drive sprocket. This locks the drive sprocket engagement with the planetary carrier. This causes the
to the mainshaft through the synchronizer. Torque is input gear to rotate the planetary pinions inside the
then transmitted through the drive sprocket to the driven annulus gear causing the planetary carrier, range shift
sprocket by the connecting drive chain. Since the front hub, and mainshaft to rotate at a gear reduction ratio of
output shaft is splined to the driven sprocket, torque 2.72:1.
flows through the output shaft to the front propeller
shaft and axle resulting in high range four-wheel drive.
DISASSEMBLY
EXTERNAL COMPONENTS 3. Rear retainer housing bolts.
• Rear retainer bolts are shouldered.
Clean 4. Rear retainer housing from the rear case half (fig
ure 5).
• The transfer case exterior using solvent and a stiff
brush.
Figure 6—Vehicle Speed Sensor Rotor Snap Ring Figure 9— Front and Rear Case
7D2-4 NEW PROCESS 241 TRANSFER CASE
5. Vehicle speed sensor rotor snap ring from the 1. Oil pump from the pickup tube and the rear case
mainshaft (figure 6). half (figure 10).
6. Vehicle speed sensor rotor from the mainshaft (fig 2. Oil pump pickup tube, O-ring, and pump pickup
ure 7). filter from the rear case half (figure 11).
7. Rear vehicle speed sensor rotor snap ring from the 3. Mode fork shift spring from the shift rail (figure 12).
mainshaft (figure 8). 4. Snap ring from the front output shaft.
8. Case bolts from case halves. 5. Mainshaft, drive chain, and driven sprocket from
the front case half as an assembly (figure 13).
• Note two longer case bolts and washers go into
the doweled case holes. • Mode shift fork and shift rail will be removed
with the mainshaft.
9. Rear case half and oil pump as an assembly from
the front case (figure 9). 6. Synchronizer to the mainshaft snap ring (figure 14).
7. Synchronizer assembly from the mainshaft (figure
• Separate the case halves by inserting two screw
15).
drivers into the slots cast into the case ends and
8. Drive sprocket from the mainshaft.
cautiously pry apart. Do not attempt to wedge the
9. Range shift fork and range shift hub from planetary
case halves apart at any point on the mating sur
carrier.
faces. Damage to the case may result.
• It is necessary to rotate the sector with shaft to
NOTICE: Be careful n ot to damage the oil obtain clearance when removing the range fork
pum p (located in the rear case half) while (figure 16).
rem oving the rear ca se half.
INTERNAL COMPONENTS
++ Remove or Disconnect (Figures 10 through
23)
Tools Required:
J 2619-01 Slide Hammer
J 8092 Driver Handle
J 22912-1 Bearing Remover
J 29369-1 Output Shaft Bearing Remover
J 29369-2 Output Shaft Bearing Remover
J 9276-21 Slide Hammer Adapter
J 33832 Bearing Installer/Remover
Figure 13— Drive Chain, Mainshaft, and Driven Figure 15—Synchronizer Assembly
Sprocket
10. Shift lever nut, washer, shift lever, sector and shaft
assembly, plastic washer, and O-ring seal from the
front case half (figure 17).
11. Input bearing retainer bolts and input bearing
retainer from front case half (figure 18).
12. Input gear snap ring (figure 19).
13. Input bearing snap ring (figure 20).
14. Planetary carrier and input gear from the annulus
gear using a soft faced hammer (figure 21).
15. Input gear to planetary carrier assembly snap ring
(figure 22).
16. Input gear from the planetary carrier.
17. Input bearing from the front case half using
J 36370 and J 8092.
Figure 18— Removing Front Bearing Retainer Figure 21—Input and Low Gear Assembly
Important
18. Mainshaft pilot bearing from the input gear using • Be careful not to damage the synchronizer struts
J 29369-1, J 9276-21, and J 2619-01 (figure 23). when removing the sleeve from the hub.
19. Front output bearing snap ring. • The oil pump is not serviceable and should be
20. Front output shaft seal from front case half. replaced as a unit only.
6. Case halves for damaged or warped mating sur 9. Pads on mode fork and range fork for wear and
faces, cracks, porosity, or damaged thread holes. distortion.
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. Input gear, planetary carrier, and range shift hub
tooth chamfers for excessive wear.
ASSEMBLY
BEARING AND SEAL 7. Input gear to planetary carrier.
8. Thrust washer over input gear in planetary carri
REPLACEMENT er.
9. Lock ring over input gear in planetary carrier.
-►4- Install or Connect (Figures 19, 22, 25, 27, and
10. Input gear to planetary carrier snap ring (figure
- 1 28)
22).
Tools Required: 11. Bearing onto the input gear using J 36373.
J 8092 Driver Handle 12. Input bearing to the input gear snap ring (figure
J 36370 Drive Gear Needle Bearing Installer 19).
J 36371 Front and Rear Output Shaft Bearing 13. Oil seal to the rear extension.
Installer 14. Input bearing retainer seal to the input bearing
J 36372 Input Gear Bearing Installer (Needle retainer.
bearing) 15. Front output shaft seal to the front case half.
J 36373 Input Gear Bearing Installer (Ball 16. Magnet to front case half (figure 25).
Bearing)
• Use Dexron® III automatic transmission fluid or the
equivalent where needed in assembly.
INTERNAL COMPONENTS
1. Needle bearing into the rear case half using
J 36372 and J 8092. Assemble (Figures 3 through 17, 21, and 26)
• Bearing must be flush with boss on the case
housing. 1. Spring retainers to the synchronizer hub (figure
2. Front output bearing into front case half using 26).
J 37371 (figure 27). 2. Synchronizer hub to the synchronizer sleeve along
3. Front output bearing snap ring into front case with the three struts.
half.
4. Bearing into rear retainer housing using • Align the scribe marks previously made.
J 36371 (figure 28). 3. Main drive synchronizer stop ring to the synchro
5. Mainshaft pilot bearing into the input gear using
nizer sleeve.
J 36372 and J 8092.
6. Thrust washer into the planetary carrier.
Figure 27— Front Output Bearing Installation Figure 28— Rear Retainer Housing Bearing
NEW PROCESS 241 TRANSFER CASE 7D2-9
1. Drive sprocket to the mainshaft. • Case bolts to 31 N-m (23 lbs. ft.).
2. Synchronizer assembly to the mainshaft (figure 15).
22. Snap ring to the mainshaft (figure 8).
3. Synchronizer snap ring to the mainshaft (figure 14).
23. Vehicle speed sensor rotor onto the mainshaft (fig
4. Input gear and planetary assembly into the annulus
gear using a soft faced hammer (figure 21). ure 7).
5. Snap ring to the input bearing (figure 20). 24. Vehicle speed sensor rotor snap ring (figure 6).
6. Input bearing retainer and input bearing retainer 25. Rear retainer housing and rear retainer bolts to the
bolts to the front case half. rear case half (figure 5).
•Apply RTV, GM P/N 12345739 or the equiva •Apply threadlocker, GM P/N 12345382 or the
lent, to bearing retainer mating surfaces. equivalent, to the rear retainer housing bolts.
•Apply threadlocker, GM P/N 12345382 or the • Rear retainer housing bolts are shouldered.
equivalent, on bearing retainer bolts.
$ Tighten
% Tighten
• Rear retainer housing bolts to 41 N-m (30 lbs.
• Input bearing retainer bolts to 19 N-m (14 lbs. ft.).
ft.).
7. Shift lever O-ring seal and plastic washer to the 26. Output bearing snap ring to the mainshaft (figure
front case half (figure 17). 4).
8. Sector with shaft into the front case half (figure 17). 27. Rear extension housing and extension bolts to the
9. Shift lever, washer, and nut to the front case half rear retainer housing (figure 3).
(figure 17). •Apply RTV, GM P/N 12345739 or the equiva
lent, to the mating surfaces.
$ Tighten •Apply treadlocker, GM P/N 12345382 or the
equivalent, to the extension housing bolts.
• Shift lever nut to 27 N-m (20 lbs. ft.). • Rear retainer housing bolts are shouldered.
10. Range shift hub and the range shift fork into the
front case half (figure 16). Tighten
• It is necessary to rotate the sector to align the
range shift fork. • Bolts to 31 N-m (23 lbs. ft.).
11. Front output shaft to the front case half.
12. Driven sprocket to the chain.
13. Drive chain onto the drive sprocket located on the
EXTERNAL COMPONENTS
mainshaft (figure 13).
Install or Connect (Figures 1 and 2)
• Mainshaft assembly, driven sprocket, and drive
chain are installed into the front case half as an
1. Detent plunger, detent spring, O-ring seal, and
assembly.
detent plug to the front case half (figure 2).
• Mode shift fork assembly through the range
shift fork, onto the synchronizer sleeve, and into
Tighten
the front case half.
14. Driven gear snap ring to front output shaft.
• Detent Plug to 15 N-m (11 lbs. ft.).
15. Mode fork shift spring to the shift rail (figure 12).
16. Oil pump pickup tube, oil tube connector, and 2. Vehicle speed sensor and O-ring to the rear retain
pump pickup screen into rear case half (figure 11). er housing (figure 1).
17. Oil tube O-ring into oil pump.
18. Oil pump to the oil pickup tube (figure 10). Tighten
£
• Lubricate oil pump pickup tube with automatic
transmission fluid before installing into pump. • Sensor to 31 N-m (23 lbs. ft.).
19. Dowels into front case half.
3. Four wheel drive actuator switch and O-ring to front
• Wipe case mating surfaces clean.
case half.
•Apply RTV, GM P/N 12345739 or the equiva
lent, to case mating surfaces.
20. Rear case half over mainshaft and onto front case & Tighten
half.
• Switch to 24 N-m (17 lbs. ft.).
• Be careful not to damage the oil pump while
installing the rear case half (figure 9). 4. Front output yoke, rubber sealing washer, washer,
21. Case bolts into case halves. and yoke nut.
•Apply threadlocker, GM P/N 12345382 or the
equivalent, to the case bolts. $ Tighten
• The two longer case bolts and washers into the
doweled case holes. • Yoke nut to 200 N-m (150 lbs. ft.).
7D2-10 NEW PROCESS 241 TRANSFER CASE
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
• p ■ < :V <{$f N-m Lbs. Ft.
Case Half Bolts.................................................................................... .......................................... 31 23
Detent Plug........................................................................................... .......................................... 15 11
Drain and Fill Plugs............................................................................ .......................................... 47 35
Four Wheel Drive Actuator Switch.................................................... .......................................... 24 17
Front Propeller Shaft Yoke N ut......................................................... .......................................... 200 150
Input Shaft Retainer Bolts................................................................... .......................................... 19 14
Mainshaft Extension Housing Bolts.................................................. .......................................... 31 23
Rear Retainer Housing Bolts............................................................. .......................................... 41 30
Shift Selector Lever Nut...................................................................... .......................................... 27 20
Vehicle Speed Sensor......................................................................... .......................................... 31 23
LUBRICATION SPECIFICATIONS
Capacity.................................................................................................................................................................2.13L (4.5 pts.)
Type Recommended............................................................................................Dexron® III Automatic Transmission Fluid
T2540
SPECIAL TOOLS
1. J2619-01
7. J 33832
2. J 8092
8. J 36371
3. J 22912-1
J 36370
J 29369-1
10. J 36372
J 29369-2
11 J 36373
J 9276-21
1. SLIDE HAMMER
2. DRIVER HANDLE 7. BEARING INSTALLER/REMOVER
3. BEARING REMOVE 8. FRONT AND REAR OUTPUT SHAFT BEARING INSTALLER
4. OUTPUT SHAFT BEARING REMOVER 9. DRIVER SPROCKET NEEDLE BEARING INSTALLER
5. OUPUT SHAFT BEARING REMOVER 10. INPUT GEAR NEEDLE BEARING INSTALLER
6. SLIDE HAMMER 11. INPUT GEAR BALL BEARING INSTALLER
V2832
NEW PROCESS 231 TRANSFER CASE 7D3-1
SECTION 7D3
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................7D3- 1
Model 2 3 1 ............................................................................................................................................................... 7D3- 1
Identification....................................................................................................................................................... 7D3- 1
Power Flow ......................................................................................................................................................... 7D3- 1
Disassembly............................................................................................................................................................... 7D3- 3
External Components........................................................................................................................................... 7D3- 3
Mainshaft Extension and Rear Retainer Housing......................................................................................... 7D3- 3
Internal Components............................................................................................................................................ 7D3- 6
Cleaning and Inspection......................................................................................................................................... 7D3-10
Assembly.....................................................................................................................................................................7D3-10
Bearing and Seal Replacement......................................................................................................................... 7D3-10
Internal Components............................................................................................................................................ 7D3-11
External Components........................................................................................................................................... 7D3-12
Specifications............................................................................................................................................................ 7D3-12
Fastener Tightening Specifications...................................................................................................................7D3-12
Lubrication Specifications...................................................................................................................................7D3-12
Special Tools............................................................................................................................................................. 7D3-13
GENERAL DESCRIPTION
MODEL 231 number. The information on this tag is necessary when
servicing this transfer case. If the tag is removed or
The Model 231 transfer case is a chain-driven,
becomes dislodged during service operations, be sure
four-position unit. It provides four-wheel drive high and
to keep the identification tag with the unit.
low ranges, a two-wheel high range and a neutral posi
tion. This model is a part-time four-wheel drive unit. POWER FLOW
Torque input in four-wheel high and low range is undif
In all drive range positions, input torque is transmitted
ferentiated. The range positions are selected by a
to the transfer case gear train through the transfer case
floor-mounted shifter. input gear. In 2HI range, torque flows from the input
The case is a two-piece aluminum case containing
gear to the range shift hub and mainshaft. Torque flow
front and rear output shafts, two drive sprockets, a shift
continues through the slip yoke which is splined to the
mechanism and a planetary gear assembly. The drive
mainshaft, and finally to the rear propeller shaft and
sprockets are connected and operated by the drive
axle. In 2HI range the mode synchronizer remains in
chain. The planetary gear assembly which consists of a
the neutral position and does not lock the drive sprock
three-pinion planetary carrier and an annulus gear pro
et to the mainshaft. As a result, torque is not transferred
vide the four-wheel drive low range when engaged. The
to the driven sprocket.
reduction ratio is 2.72:1 in this range.
In 4HI range, input torque from the input gear is
IDENTIFICATION transmitted to the mainshaft in exactly the same fashion
An identification tag is attached to the rear half of the as in 2HI range. However in the 4HI position, the mode
transfer case. This tag provides the transfer case model synchronizer sleeve is shifted into engagement with the
number, low range gear reduction ratio, and assembly clutch teeth of the drive sprocket. This locks the drive
7D3-2 NEW PROCESS 231 TRANSFER CASE
DISASSEMBLY
EXTERNAL COMPONENTS MAINSHAFT EXTENSION AND
REAR RETAINER HOUSING
Clean
Remove or Disconnect (Figures 6 through 12)
• The transfer case exterior using solvent and a stiff
brush.
1. Rear extension housing bolts and the rear exten
sion housing (figure 6).
4- + Remove or Disconnect (Figures 3, 4, and 5)
• Tap the extension housing with a rubber mallet
to free from the sealer.
1. Vehicle speed sensor (figure 3).
2. Vacuum switch and O-ring seal (figure 4). 2. Rear bearing retainer snap ring from the mainshaft
3. Detent plug, detent spring, and detent plunger from (figure 7).
the case (figure 5). 3. Rear retainer housing bolts.
7D3-4 NEW PROCESS 231 TRANSFER CASE
Important
Figure 5— Detent Plug, Spring, and Plunger • Note: The two longer case bolts and washers
go into the doweled case holes.
NEW PROCESS 231 TRANSFER CASE 7D3-5
Figure 8—Rear Retainer Housing Figure 11—Rear Vehicle Speed Sensor Rotor Snap
Ring
INTERNAL COMPONENTS 1. Oil pump from the pickup tube and rear case half
(figure 13).
+-► Remove or Disconnect (Figures 13 through 2. Oil pump pickup tube, O-ring, and pump pickup
filter from the rear case half (figure 14).
29) 3. Mode fork shift spring from the shift rail (figure 15).
4. Front output shaft seal from the front case half.
Tools Required: 5. Front output shaft snap ring (figure 16).
J 8092 Driver Handle 6. Mainshaft, drive chain, and driven sprocket from
J 36370 Bearing Installer/Remover
the front case half as an assembly (figure 17).
J 29170 Bearing Remover
J 29369-1 Bearing Remover • Mode shift fork and shift rail will be removed
J 9276-21 Adapter with the mainshaft.
J 2619-01 Slide Hammer
7. Synchronizer to mainshaft snap ring (figure 18).
J 33790 Bearing Remover
8. Synchronizer assembly from the mainshaft (figure
19).
Important
9. Drive sprocket from the mainshaft.
10. Range shift fork and range shift hub from the plan
The annulus gear found in this transfer case is not
etary carrier (figure 20).
serviceable or removable, and should only be replaced
as a unit with the front case half. If the annulus gear is • It is necessary to rotate the sector shaft to
removed, damage will occur to the case. obtain clearance when removing the range fork.
NEW PROCESS 231 TRANSFER CASE 7D3-7
Figure 17— Drive Chain, Mainshaft, and Driven Figure 19—Synchronizer Assembly
Sprocket
Figure 22— Removing Front Bearing Retainer Figure 24—Input and Low Range Gear Assembly
NEW PROCESS 231 TRANSFER CASE 7D3-9
Figure 25— Input Gear Figure 27—Front Output Bearing Snap Ring
Figure 26— Input Gear Bearing Removal Figure 28—Front Output Rear Bearing Removal
7D3-10 NEW PROCESS 231 TRANSFER CASE
ASSEMBLY
BEARING AND SEAL 1. Needle bearings into the rear case half using
J 33832 and J 8092.
REPLACEMENT
• Bearing must be flush with the boss on case
+ 4- Install or Connect (Figures 25, 29, 31, and 32) housing.
2. Front output bearing into the front case half using
Tools Required: J 8092 and J 33833.
J 8092 Driver Handle 3. Front output bearing snap ring.
J 33833 Bearing Installer 4. Bearing into the rear retainer housing using
J 36372 Bearing Installer J 33833 and J 8092 (figure 31).
J 33843 Seal Installer 5. Bearing into the input gear using J 36372 and
J 33831 Seal Installer J 8092.
J 33832 Bearing Installer 6. Thrust washer into planetary carrier (figure 25).
• Use Dexron® III automatic transmission fluid or the 7. Input gear and thrust washer into planetary carrier
equivalent for lubricant during assembly. (figure 25).
NEW PROCESS 231 TRANSFER CASE 7D3-11
INTERNAL COMPONENTS
* Assemble (Figures 18, 19, and 30)
Install or Connect (Figures 6, 7, 9, 10, 11, 13, >>• 12. Oil tube O-ring onto the oil pump pickup tube.
14, 15, 17, 20, 21, 23, and 24) NOTICE: Do not damage the O-ring during
1. Planetary input gear assembly through the input
assem b ly as this could result in pum p failure.
bearing into the annulus using a soft faced hammer
(figure 24). 13. Oil pump to the oil pump pickup tube (figure 13).
2. Input gear snap ring (figure 23). •Apply RTV sealer (GM P/N 12345739) or the
3. Input bearing retainer and input bearing retainer equivalent to the case mating surfaces.
bolts to front case half. 14. Rear case over mainshaft and onto the front case
•Apply RTV (GM P/N 12345739) or the equiva half.
lent on bearing retainer mating surfaces. • Be careful not to damage the oil pump when
•Apply threadlocker (GM P/N 12345382) or the installing the case halves together.
equivalent to bearing retainer bolts. 15 Case bolts into case halves.
Tighten •A pply threadlocker (GM P/N 12345382) or
& equivalent to the case bolts.
• The two longer case bolts and washers into the
• Input bearing retainer bolts to 19 N-m (14 lbs.
doweled case holes, or from their original holes
ft.).
on transfer cases with attaching brackets.
4. Shift lever O-ring, plastic washer, into front case
half.
Tighten
5. Sector with shaft into the front case half, shift lever,
washer, and nut to the front case half (figure 21).
• Case bolts to 31 N-m (23 lbs. ft.).
Tighten 16. Snap ring to the mainshaft (figure 11).
17. Vehicle speed sensor rotor onto mainshaft (figure
• Shift lever nut to 27 N-m (20 lbs. ft.). 10).
6. Range shift hub and range shift fork into the front 18. Vehicle speed sensor rotor snap ring (figure 9).
case half (figure 20). 19. Rear retainer housing and rear retainer housing
• It is necessary to rotate the sector to align the bolts to the rear case half.
range shift fork. •A pply threadlocker (GM P/N 12345382) or
7. Chain over main shaft onto drive gear (figure 17). equivalent to the rear retainer housing bolt
• Install mainshaft assembly, chain and front out threads.
put shaft into case as an assembly. • Apply RTV (GM P/N 12345739) or equivalent at
8. Mainshaft assembly, mode shift fork, and rail the joint.
through range shift fork into front case half (figure
17). “ $ Tighten
9. Front output shaft into chain and into front case
half. • Rear retainer housing bolts to 41 N-m (30 lbs.
10. Fork shift spring onto the mode shift rail (figure 15). ft.).
11. Oil pickup tube, oil tube connector, and pump pick 20. Output bearing snap ring to the mainshaft (figure
up screen into the rear case half (figure 14). 7)-
7D3-12 NEW PROCESS 231 TRANSFER CASE
Tighten
EXTERNAL COMPONENTS
++ Install or Connect (Figures 3 through 5)
& Tighten
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N-m Ft. Lbs.
Case Half Bolts............................................................................................................................... ......... 31 23
Detent Plug................................................................................................................................................15 11
Fill and Drain Plugs....................................................................................................................... .........47 35
Input Shaft Bearing Retainer Bolts........................................................................................................19 14
Mainshaft Extension Housing Bolts.......................................................................................................31 23
Rear Retainer Housing Bolts........................................................................................................ .........31 23
Shift Selector Lever Nut................................................................................................................. .........31 23
Shift Selector Vacuum Switch....................................................................................................... .........24 17
Vehicle Speed Sensor.................................................................................................................... .........31 23
LUBRICATION SPECIFICATIONS
Capacity.................... ............................................1.18L (1.25 qts.)
Type Recommended Dexron® III Automatic Transmission Fluid
T2541
NEW PROCESS 231 TRANSFER CASE 7D3-13
SPECIAL TOOLS
1. SLIDE HAMMER
2. DRIVER HANDLE 8. BEARING INSTALLER
3. BEARING REMOVER 9. BEARING INSTALLER
4. BEARING REMOVER 10. SEAL INSTALLER
5. OUTPUT SHAFT BEARING REMOVER 11. EXTENSION HOUSING SEAL INSTALLER
6. ADAPTER 12. BEARING INSTALLER
7. BEARING INSTALLER 13. BEARING REMOVER
V2831
NOTES
'
OTtPS I
s-e^sas i
-r r -s r y r
',v. o w X S a ' i
j v 1S 3 / J
\ m ■ AT8W
h mj s\-
r, :
BORG-WARNER 4401 TRANSFER CASE 7D4-1
SECTION 7D4
BORG-WARNER 4401
TRANSFER CASE
NOTICE: When fasteners are removed, always reinstall them at the sam e location from which they were
removed. If a fastener n eed s to be replaced, u se 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. Fasteners that are not reused, and those requiring thread locking com pound will be called out.
The correct torque value m u st be u sed when installing fasteners that require it. If the above conditions
are not followed, parts or sy ste m damage could result.
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................7D4- 1
4401 Transfer Case................................................................................................................................................7D4- 1
Identification....................................................................................................................................................... 7D4- 1
Power Flow ......................................................................................................................................................... 7D4- 1
Disassembly............................................................................................................................................................... 7D4- 2
External Components........................................................................................................................................... 7D4- 2
Internal Components............................................................................................................................................ 7D4- 2
Synchronizer Hub Assembly.............................................................................................................................. 7D4- 4
Oil Pump Assembly.............................................................................................................................................. 7D4- 4
Cleaning and Inspection......................................................................................................................................... 7D4- 6
Assembly.....................................................................................................................................................................7D4- 7
Oil Pump Assembly.............................................................................................................................................. 7D4- 7
Synchronizer Hub Assembly.............................................................................................................................. 7D4- 7
Internal Components............................................................................................................................................ 7D4- 7
External Components........................................................................................................................................... 7D4- 8
Specifications............................................................................................................................................................ 7D4- 9
Fastener Tightening Specifications..................... .............................................................................................7D4- 9
Lubrication Specifications...................................................................................................................................7D4- 9
Special Tools............................................................................................................................................................. 7D4-10
GENERAL DESCRIPTION
4401 TRANSFER CASE sary for servicing information. If the tag is removed or
becomes dislodged during service operations, make
The Borg-Warner 4401 transfer case is a chain driv
sure to keep the identification tag with the unit.
en, four-position unit providing four-wheel drive high
and low ranges, a two-wheel high range, and a neutral POWER FLOW
position. The BW4401 is a part-time four-wheel drive
unit. Torque input in four-wheel drive is undifferentiated. In all drive range positions input torque is transmitted
The range positions are selected by a floor-mounted to the transfer case gear train through the transfer case
gear shift lever. The unit has a gear reduction ratio of input gear.
2.69:1. In 2HI range, torque flows from the input gear to the
The BW4401 has a three-piece aluminum case with range shift hub and mainshaft. Torque flow continues
provisions for a power take off (PTO) and uses an elec through the slip/fixed yoke which is splined to the main
tric synchronizer when shifting into four-wheel drive. shaft, and finally to the rear propeller shaft and axle. In
2HI range, the mode synchronizer remains in the neu
IDENTIFICATION tral position. As a result, torque is not transferred to the
The identification tag is an aluminum tag attached driven sprocket.
under the self-tapping extension housing bolts. This tag In 4HI range, input torque from the input gear is
provides the transfer case model number, serial number transmitted to the mainshaft in exactly the same fashion
and the build date. The information on this tag is neces as in 2HI range. However, in 4HI position, the mode
7D4-2 BORG-WARNER 4401 TRANSFER CASE
synchronizer sleeve is shifted into engagement with the In 4LO 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. In 4LO range the range hub is shifted
assembly. Torque is transmitted through the drive into engagement with the planetary carrier. This causes
sprocket by the connecting drive chain. Since the front the input gear to rotate the planetary pinions inside the
output shaft is splined to the driven sprocket, torque fixed annulus gear, causing the planetary carrier, range
flows through the front output shaft to the front propeller shift hub, and mainshaft to rotate at a gear reduction of
shaft and axle resulting in high range four-wheel drive. 2.69:1.
DISASSEMBLY
EXTERNAL COMPONENTS J 2619-01 Slide Hammer
J 29369-1 Output Shaft Bearing Remover
Clean 1. Speedometer tone wheel from the mainshaft using
J 22912-01 and J 8433-4 or equivalent (figure 2).
• The transfer case using a solvent and a stiff brush. • Be careful not to install J 22912-01 under the
tone wheel snap ring.
E3 Remove or Disconnect (Figure 1) 2. Tone wheel snap ring from the mainshaft.
3. Rear output bearing snap ring from the mainshaft
1. Front output yoke nut, flat washer, rubber sealing using J 8059 (figure 3).
washer, and the front output yoke from the front
output shaft.
2. Rear output yoke nut, flat washer, rubber sealing
washer, and the rear output yoke from the main
shaft (figure 1).
3. Speed sensor from the rear bearing retainer.
4. Four-wheel drive indicator switch from the front
case half.
5. Rear bearing retainer bolts and rear bearing retain
er from the rear case half.
INTERNAL COMPONENTS
Remove or Disconnect (Figures 2 through 20)
B
Tools Required:
J 22912-01 Gear Puller
J 8433-4 Puller
J 8059 Snap Ring Pliers
J 8092 Driver Handle
J 29169 Bearing Remover/Installer
J 33832 Bearing Remover/Installer Figure 2—Speedometer Tone Wheel Removal
8059
Figure 4—Clutch Coil Figure 6—Shift Mode Fork and the Synchronizer
Assembly
Figure 9—Mainshaft and Oil Pump Figure 11—Annulus Gear Snap Ring
26. Front input bearing snap ring from the front case SYNCHRONIZER HUB
(figure 16).
27. Front input bearing from the front case using
ASSEMBLY
J 8092 and J 29169 (figure 17).
28. Rear output bearing from the rear case half using * Disassemble
J 8092 and J 33832.
29. Front output shaft rear bearing from the rear case 1. Synchronizer hub snap ring from the synchronizer
using J 2619-01 and J 29369-1 (figure 18). hub assembly (figure 21).
30. Front output shaft seal from the front case. 2. Lockup hub compression spring from the lockup
31. Front output bearing snap ring from the front case collar.
(figure 19).
32. Front output bearing from the front case using OIL PUMP ASSEMBLY
J 8092 and J 33832 (figure 20).
33. Rear output shaft seal from the rear bearing retain Disassemble
er.
*
1. Oil pump retainer bolts and oil pump retainer from
the oil pump rear cover.
BORG-WARNER 4401 TRANSFER CASE 7D4-5
J 29169
Figure 17—Front Input Bearing Removal Figure 19— Front Output Bearing Snap Ring
Figure 18— Front Output Shaft Rear Bearing Figure 20—Front Output Bearing Removal
Removal
9. Pads on the mode fork and the range fork for wear 11. Input gear, planetary carrier, and range shift hub
or distortion. tooth chamfers for excessive wear.
10. Oil pump pins and housing, mainshaft pin pump 12. Speedometer tone wheel for wear, spalling, and
bores for wear, spalling, cracks, and damage. cracks.
Replace complete assembly if there is wear.
ASSEMBLY
During assembly of the transfer case, lubricate all Tighten
necessary parts with Dexron® III automatic transmis
sion fluid or the equivalent. • Bolts to 6.2 N.m (55 lbs. in.).
* Assemble (Figure 25) • Oil pump operation on the mainshaft. The main
shaft must turn freely within the oil pump. If
1. Oil pump pickup to the pickup tube. binding occurs, loosen the four bolts and retor
2. Pickup tube, oil pump pickup, and retainer to the oil que.
pump housing.
3. The oil pump front cover with the word TOP facing
the front of the front case.
SYNCHRONIZER HUB
4. Oil pump pins, flats facing rearward toward the out ASSEMBLY
put end of shaft, oil pump spring between the two
pins and place the assembly into the oil pump bore Assemble (Figure 21)
in the mainshaft.
5. Oil pump housing to the mainshaft making sure the 1. Compression spring to the lockup collar.
oil pump pins are riding against the inside of the 2. Lockup hub compressing the compression spring.
pump housing. 3. Synchronizer hub snap ring.
• Lubricate the assembly with automatic transmis
sion fluid. INTERNAL COMPONENTS
6. Oil pump rear cover with the words TOP REAR
Install or Connect (Figures 4 through 16, 19,
facing the rear of the transfer case.
• Note that the word TOP on the front and rear 22, and 23)
covers should be on the same side.
Tools Required:
7. Oil pump retainer with the tabs facing the front of
the transfer case. J 37668 Seal Installer
8. Oil pump retainer bolts and rotate the mainshaft J 8092 Driver Handle
while tightening the bolts to prevent the pump from J 33832 Bearing Installer/Remover
binding. J 29169 Bearing Installer/Remover
1. Rear output shaft seal to the rear bearing retainer 23. Synchronizer assembly and mode shift fork align
using J 37668. ing the synchronizer assembly to the mainshaft
2. Front output bearing to the front case using J 8092 drive gear and the mode fork to the shift rail (figure
and J 33832 (figure 22). 6 ).
3. Front output bearing snap ring to the front case 24. Synchronizer hub to the synchronizer assembly.
(figure 19). 25. Clutch coil housing and clutch coil housing snap
4. Front output shaft seal to the front case using ring to the mainshaft (figure 5).
J 37668. 26. Shift rail spring to the shift rail.
5. Rear output bearing to the rear case using J 8092 27. Clutch coil to the rear case.
and J 33832. 28. Clutch coil nuts to the clutch coil (figure 4).
6. Front input bearing to the front case using J 8092
and J 29169 (figure 23). Tighten
7. Front input bearing snap ring to the front case (fig
ure 16). • Clutch coil nuts to 10 N.m (89 lbs. in.).
8. Sector, detent spring, and detent roller to the front
case (figure 15). 29. Clutch coil wire through the rear case and clutch
9. Sector shaft through the case and align with spline coil wire connector to the clutch coil wire (figure 4).
on the sector. 30. RTV sealer (GM P/N 12345739) or the equivalent
10. Retainer clip to the sector shaft. to the case sealing surfaces and the rear case half
11. Power take off drive gear and the input carrier to the front case half.
assembly to the front case (figure 14). 31. Case bolts to the case halves.
12. Input carrier snap ring to the input carrier (figure
13). % Tighten
13. Input shaft front oil seal to the front case using
J 37668. • Case bolts to 31 N.m (23 lbs. ft.).
14. Annulus gear to the front case (figure 12).
32. A new speedometer tone wheel to the mainshaft
15. Annulus gear snap ring to the front case (figure
using J 5590.
11).
16. Range fork and shaft hub aligning the shift hub to
Important
the carrier assembly and the shift fork pin to the
slot in the sector (figure 10).
17. Shift rail through the range fork and into the boss The speedometer tone wheel is important to the prop
in the front case (figure 10). er operation of the anti-lock braking system, speedome
18. Mainshaft and oil pump assembly into the carrier ter/odometer, cruise control and the PCM. Use care not
assembly (figure 9). to damage it upon installation.
19. Front output shaft to the front output bearing.
20. Drive gear, driven gear, and drive chain as an EXTERNAL COMPONENTS
assembly to the mainshaft and front output shaft
(figure 8). -*+■ Install or Connect (Figure 1)
21. Flat washer to the front output shaft.
22. Front output shaft snap ring to the front output 1. RTV sealer (GM P/N 12345739) or the equivalent
shaft (figure 7). to the rear bearing retainer sealing surfaces.
2. Rear bearing retainer bolts to the rear case.
£ Tighten
Tighten
Tighten
Tighten
• Nut to 170 N.m (125 lbs. ft.). * Nut t0 224 N m (165 lbs- ft-)-
SPECIFICATIONS
FASTENER TIG HTENING SPECIFICATIONS
N-m Lbs. Ft. Lbs. In.
Case and Rear Bearing Retainer Screws.......................................................... 41 30 —
Clutch Coil Nuts.......................................................... .......................................... 10 — 84
Drain/Fill Plugs.................... ,................... .............................................................. 25 18 —
Yoke Nut (Front Output)..................................................... .......... ........................ 224 165 —
Four Wheel Drive Indicator Switch...................................................................... 27 20 —
Oil Pump Retainer Bolts......................................................................... ............. 6.2 — 55
P.T.O. Cover Bolts.................................................................................................. 27 20 —
Vehicle Speed Sensor Retaining Bolt................................................................. 16 12 —
Vent........................................................................................................................... 14 10 —
Yoke Nut (Rear Output)......................................................................................... 170 125 —
LUBRICATION SPECIFICATIONS
Capacity...................................................................................................................................................................1.5L (1.6 qts.)
Type Recommended.................................................................... Dexron® III Automatic Transmission Fluidor equivalent
T2542
7D4-10 BORG-WARNER 4401 TRANSFER CASE
SPECIAL TOOLS
J 22912-01 J 8092
J 8433-4 8. J 5590
9. J 29369-1
3. J8059
5. J 33832
1. Bearing and Gear Puller
2. Puller
3. Snap Ring Pliers
4. Bearing Remover/Installer
5. Bearing Remover/Installer
6. J 37668 6. Seal Installer
7. Driver Handle
8. Installer
9. Output Shaft Bearing Remover
10. Slide Hammer
F7663
BORG-WARNER 4472 TRANSFER CASE 7D5-1
SECTION 7D5
CONTENTS
SUBJECT PAGE
General Description....................................................................................................................................................7D5-1
BW4472 Transfer Case.............. .............................................................................................................................7D5-1
Identification......................................................................................................................................................... 7D5-1
Power F low ........................................................................................................................................................... 7D5-1
Disassembly..................................................................................................................................................................7D5-2
External Components..............................................................................................................................................7D5-2
Internal Components...............................................................................................................................................7D5-2
Bearings and Seals.................................................................................................................................................7D5-4
Cleaning and Inspection............................................................................................................................................7D5-6
Assembly....................................................................................................................................................................... 7D5-6
Specifications.............................................................................................................................................................. 7D5-8
Fastener Tightening Specifications.....................................................................................................................7D5-8
Lubrication Specification....................................................................................................................................... 7D5-8
Special Tools................................................................................................................................................................7D5-9
GENERAL DESCRIPTION
BW 4472 TRANSFER CASE IDENTIFICATION
The identification tag is an aluminum tag attached
The BW4472 is a three-piece aluminum, chain driven, under one of the self-tapping case bolts. The tag pro
viscous clutch-type transfer case. This is used in a sys vides the Borg-Warner part number, General Motors
tem in which all-wheel drive is always activated. The part number, serial number, and the build date. The
all-wheel drive is automatic and has no external con information on the tag is necessary for servicing infor
trols. mation. If the tag is removed or becomes dislodged
The viscous clutch used in the BW4472 is a torque during service operations, be sure to keep the identifi
cation tag with the unit.
distribution device and is nonserviceable. The internal
construction of the viscous clutch consists of alternating POWER FLOW
plates that are connected to the front and rear outputs Torque is transmitted through the input shaft to the
of the transfer case. The clutch is filled with a high-vis- planet carrier assembly. Torque flow continues through
cosity fluid which flows through slots in the plates. The the ring gear to the rear output shaft. Torque is trans
fluid’s resistance to sheering causes the plates to trans mitted from the planet carrier assembly to the sun gear
mit torque at the needed ratio to the front or rear shaft which is splined to the drive sprocket. The drive
gear is connected to the driven sprocket by the drive
wheels. Ratio that torque is transmitted is approximately
chain. Torque continues through the driven sprocket to
35 percent front, 65 percent rear.
the front output shaft flange. The viscous clutch pro
vides the connection between the ring gear and the sun
gear shaft.
7D5-2 BORG-WARNER 4472 TRANSFER CASE
DISASSEMBLY
EXTERNAL COMPONENTS
Clean • Use care when prying apart the case so that
you do not damage the case sealing surfaces.
The transfer case using solvent and a stiff brush. 5. Front cover by prying on the tabs provided (figure
2 ).
Remove or Disconnect (Figures 1 and 2)
INTERNAL COMPONENTS
1. Front output flange nut, steel flat washer, and rub
ber sealing washer from the front output shaft (fig
Remove or Disconnect (Figures 3 through 12)
ure 1).
2. Front output flange from the front output shaft (fig
ure 1). 1. Front output shaft spacer from the front output
3. Speed sensor bolt and speed sensor from the shaft (figure 3).
extension housing. 2. Front output shaft, drive chain, and driven sprocket
4. Front cover bolts from the rear case half. from the rear case half (figure 4).
11. Output shaft bearing snap ring from the output 1. Front output shaft oil seal from the front cover (fig
shaft bearing (figure 10). ure 13).
12. Input shaft bearing, Output shaft, and ring gear as 2. Input shaft oil seal from the front cover (figure 13).
an assembly,from the rear case half. 3. Output shaft bearing snap ring from the front cover
13. Ring gear snap ring from the ring gear (figure 11). (figure 14).
14. Output shaft assembly from the ring gear (figure 4. Output shaft bearing from the front cover using
12). J 2619-01 and J 29369-1 (figure 15).
5. Output shaft oil seal from the extension housing
BEARINGS AND SEALS (figure 16).
6. Using J 22912-01, press the sun gear shaft bearing
Remove or Disconnect (Figures 13 through 19) from the sun gear shaft (figure 17).
• Remove the drive sprocket spacer, drive
Tools Required: sprocket, and the viscous clutch from the sun
J 22912-01 Bearing Remover gear shaft.
J 23907 Puller 7. Input shaft pilot bearing from the output shaft
J 2619-01 Slide Hammer assembly using J 23907 (figure 18).
J 29369-1 Front Output Shaft Front Bearing 8. Output shaft rear bearing from the rear case half
Remover using J 23907 and J 38427 (figure 19).
J 38427 Front Output Shaft Rear Bearing
Remover
Figure 15—Front Output Bearing Removal Figure 18—Input Shaft Pilot Bearing Removal
J 38427 J 23907
Figure 16— Output Shaft Oil Seal Figure 19—Front Output Shaft Rear Bearing Removal
7D5-6 BORG-WARNER 4472 TRANSFER CASE
ASSEMBLY
Tools Required: 5. Output shaft bearing to the front cover using
J 7079-2 Driver Handle J 8092 and J 38423 (figure 21).
J 38212 Needle Bearing Installer 6. Output shaft bearing snap ring to the front cover
J 38423 Front Output Shaft Front Bearing (figure 14).
Installer 7. Output shaft rear bearing to the rear case half
J 8092 Driver Handle using J 7079-2 and J 38212 (figure 22).
During assembly of the transfer case, lube all neces
sary parts with Dexron® III Automatic Transmission Flu -►«- Install or Connect (Figures 1, 3 through 10,
id or the equivalent. — 1 16, and 23)
J 7 0 7 9 -2
J 38212
HI Tighten
J 38212
• Speed sensor bolt to 16 N-m (12 lbs. ft.).
$*
6. Output shaft oil seal to the extension housing using
J 37668. Align the water drain hole in the output
shaft oil seal with the drain groove in the extension
housing (figures 16 and 23).
7. Planet carrier assembly thrust washer to the output
shaft assembly using petroleum jelly and align with
the input shaft pilot bearing.
8. Planet carrier assembly into the ring gear (figure
8).
9. Sun gear shaft thrust washer to the planet carrier
assembly using petroleum jelly (figure 7).
10. Sun gear shaft assembly into the planet carrier
assembly planet gears and align the viscous clutch
teeth to the ring gear spline (figure 6).
11. Input shaft into the input shaft pilot bearing aligning
Figure 22— Front Output Shaft Rear Bearing the input shaft with the sun gear shaft thrust wash
Installation er and the planet carrier assembly thrust washer
(figure 5).
12. Driven sprocket onto the front output shaft.
• Install the driven sprocket with the letter “E”
J 37668 facing down.
■^
13. Drive chain onto the driven sprocket.
14. Drive chain over the drive sprocket and the front
output shaft into the output shaft rear bearing (fig
ure 4).
15. Front output shaft spacer onto the front output
shaft (figure 3). ,
16. Magnet to the rear case half.
17. Apply an 1/8-inch bead of RTV sealer (GM P/N
12345739) or the equivalent to the rear case half
front cover sealing surface.
18. Front cover and front cover bolts to the rear case
half. v
HI Tighten
Figure 23—Installing the Output Shaft Oil Seal • Front cover bolts to 42 N-m (30 lbs. ft.).
3. Apply an 1/8-inch bead of RTV sealer (GM P/N 19. Front output shaft oil seal to the front cover using
12345739) or the equivalent to the rear case half J 37668.
extension housing sealing surface. 20. Input shaft oil seal using J 38216.
4. Extensioh housing and the extension housing bolts 21. Front output flange to the front output shaft (figure
to the rear case half (figure 9). 1).
22. Rubber sealing washer, steel flat washer, and a
new front output flange nut (figure 1).
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N-m Lbs. Ft. Lbs. In.
Drain/Fill Plugs....................................................................................................... 25 18 *: * —
Extension Housing Bolts....................................................................................... 42 30 —
Front Cover Bolts................................................................................................... 42 30 —
Front Output Flange Nut....................................................................................... 108 80 —
Speed Sensor Bolt................................................................................................. 16 12 —
LUBRICATION SPECIFICATIONS
Capacity...................................................................................................................................................................1.2L (1.3 qts.)
Type Recommended............................................................................................Dexron® III Automatic Transmission Fluid
T2380
BORG-WARNER 4472 TRANSFER CASE 7D5-9
SPECIAL TOOLS
7. J 37668
1. J 22912-01
J 38216
2. J 23907
]pSa
J 2619-01
GM P/N 1052366
10 . J 38427
J 29369-1
11 J 38423
5. J 7079-2
12 . 8092
J 38212
SECTION 7D6
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................7D6- 1
BW4470 Transfer Case......................................................................................................................................... 7D6- 1
Identification....................................................................................................................................................... 7D6- 1
Power Flow ......................................................................................................................................................... 7D6- 1
Disassembly............................................................................................................................................................... 7D6- 2
External Components........................................................................................................................................... 7D6- 2
Internal Components............................................................................................................................................ 7D6- 2
Synchronizer Hub Assembly.............................................................................................................................. 7D6- 5
Oil Pump Assembly...............................................................................................................................................7D6- 5
Cleaning and Inspection......................................................................................................................................... 7D6- 6
Assembly.....................................................................................................................................................................7D6- 7
Oil Pump Assembly.............................................................................................................................................. 7D6- 7
Synchronizer Assembly....................................................................................................................................... 7D6- 7
Internal Components............................................................................................................................................ 7D6- 7
External Components........................................................................................................................................... 7D6- 8
Specifications............................................................................................................................................................ 7D6- 9
Fastener Tightening Specifications...................................................................................................................7D6- 9
Lubrication Specifications...................................................................................................................................7D6- 9
Special Tools............................................................................................................................................................. 7D6-10
GENERAL DESCRIPTION
necessary for servicing information. If the tag is
BW 4470 TRANSFER CASE removed or becomes dislodged during service opera
The Borg-Warner 4470 transfer case is a chain-driv- tions, be sure to keep the identification tag with the unit.
en, four-position unit providing four-wheel drive high
and low ranges, a two-wheel high range, and a neutral POWER FLOW
position. The BW4470 is a part-time four-wheel drive In all drive range positions, input torque is transmitted
unit. Torque input in four-wheel drive is undifferentiated. to the transfer case gear train through the transfer case
The range positions are selected by a floor-mounted input gear.
gear shift lever. The unit has a gear reduction ratio of In the 2HI range, torque flows from the input gear to
2.69:1. the range shift hub and mainshaft. Torque flow contin
The BW4470 has a three-piece aluminum case with ues through the slip/fixed yoke which is splined to the
provisions for a power take off (PTO) and uses an elec mainshaft, and finally to the rear propeller shaft and
tric synchronizer when shifting into four-wheel drive. axle. In the 2HI range, the mode synchronizer remains
in the neutral position. As a result, torque is not trans
IDENTIFICATION
ferred to the driven sprocket.
The identification tag is an aluminum tag attached In the 4HI range, input torque from the input gear is
under the self-tapping extension housing bolts. This tag transmitted to the mainshaft in exactly the same fashion
provides the transfer case model number, serial num as in 2HI range. However, in 4HI position, the mode
ber, and the build date. The information on this tag is synchronizer sleeve is shifted into engagement with the
7D6-2 BORG-WARNER 4470 TRANSFER CASE
clutch hub teeth on the mainshaft. This locks the drive In the 4LO range, the path of torque through the
sprocket to the main shaft through the synchronizer transfer case is exactly the same as in 4HI range but,
assembly. Torque is transmitted through the drive with one major difference. In the 4LO range the range
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. This causes the input gear to rotate the planetary
flows through the front output shaft to the front propeller pinions inside the annulus gear, causing the planetary
shaft and axle resulting in high range four-wheel drive. carrier, range shift hub, and mainshaft to rotate at a
gear reduction of 2.69:1.
DISASSEMBLY
EXTERNAL COMPONENTS J 2619-01 Slide Hammer
J 29369-1 Output Shaft Bearing Remover
jjj Clean 1. Speedometer tone wheel from the mainshaft using
J 22912-01 and J 8433-4 (figure 2).
• Be careful not to install J 22912-01 under the
• The transfer case using solvent and a stiff brush.
tone wheel snap ring.
Remove or Disconnect (Figure 1) 2. Tone wheel snap ring from the mainshaft.
3. Rear output bearing snap ring from the mainshaft
using snap ring pliers (figure 3).
1. Front output yoke nut, flat washer, rubber sealing
washer, and the front output yoke from the front
output shaft.
2. Rear output yoke nut, flat washer, rubber sealing
washer, and the rear output yoke from the main
shaft.
3. Speed sensor from the rear bearing retainer.
4. Four-wheel drive indicator switch from the front
case half.
5. Rear bearing retainer bolts and rear bearing retain
er from the rear case half.
INTERNAL COMPONENTS
Remove or Disconnect (Figures 3 through 23)
Tools Required:
J 22912-01 Gear Puller
J 8433-4 Puller
J 8092 Driver Handle
J 29169 Bearing Remover/Installer
J 33832 Bearing Remover/Installer
Figure 1—Rear Output Yoke Figure 3—Rear Output Bearing Snap Ring
BORG-WARNER 4470 TRANSFER CASE 7D6-3
Assembly
Figure 14— Input Carrier and PTO Gear Figure 17—Front Input Bearing Removal
SYNCHRONIZER HUB
ASSEMBLY
❖ Disassemble (Figure 21)
J 33832
J 8092
1. Bearings. L* Inspect
2. Shafts.
3. Sprockets. 1. Bearings and thrust washers for wear, spalling,
4. Chain. brinelling, or corrosion.
5. Oil feed ports and channels in each case half. 2. Gear teeth for excessive wear or damage, spalling,
Apply compressed air to each oil feed port and cracks, or corrosion.
channel in order to remove any obstructions or 3. Gear splines for excessive wear, spalling, cracks,
cleaning solvent residue. twist, or corrosion.
BORG-WARNER 4470 TRANSFER CASE 7D6-7
4. Shaft splines for excessive wear, spalling, cracks, 8. Synchronizer hub and sleeve for cracks, chips,
distortion, or corrosion. spalling, or excessive wear.
5. Retainer rings for excessive wear, distortion, or 9. Pads on the mode fork and the range fork for wear
damage. or distortion.
6. Case halves for damaged or warped mating sur 10. Oil pump gears, housing, and mainshaft for wear,
faces, cracks, porosity, or damaged thread holes. spalling, cracks, and damage. Replace complete
7. Synchronizer assembly for cracks, chips, spalling, assembly if there is wear.
or excessive wear. 11. Input gear, planetary carrier, and range shift hub
tooth chamfers for excessive wear.
ASSEMBLY
During assembly of the transfer case, lubricate all SYNCHRONIZER HUB
necessary parts with Dexron® III automatic transmis
sion fluid or the equivalent. ASSEMBLY
OIL PUMP ASSEMBLY * Assemble (Figure 21)
J 8092
J 8092 J 29169
Figure 23— Front Output Bearing Installation Figure 24— Front Input Bearing Installation
16. Range fork and shaft hub aligning the shift hub to 32. Rear output bearing snap ring to the mainshaft (fig
the carrier assembly and the shift fork pin to the ure 3).
slot in the sector (figure 10).
17. Shift rail through the range fork and into the boss
NOTE: The speedom eter tone wheel is impor
in the front case (figure 10).
tant to the proper operation o f the anti-lock
18. Mainshaft and oil pump assembly into the carrier
b ra kin g s y s te m , s p e e d o m e te r /o d o m e te r ,
assembly (figure 9). cruise control, and the PCM. If it is removed,
19. Front output shaft to the front output bearing. it m u st be replaced with a new part and the
20. Drive gear, driven gear, and drive chain as an old part should be discarded. Use care not to
assembly to the mainshaft and front output shaft damage it upon installation.
(figure 8).
21. Flat washer to the front output shaft.
22. Front output shaft snap ring to the front output 33. A new speedometer tone wheei to the mainshaft
shaft (figure 7). using J 5590.
23. Synchronizer assembly and mode shift fork align
ing the synchronizer assembly to the mainshaft EXTERNAL COMPONENTS
drive gear and the mode fork to the shift rail (figure
Install or Connect (Figure 1)
6).
24. Synchronizer hub to the synchronizer assembly.
25. Clutch coil housing and clutch coil housing snap 1. RTV sealer (GM P/N 12345739) or the equivalent
ring to the mainshaft (figure 5). to the rear bearing retainer sealing surfaces.
2. Rear bearing retainer bolts to the rear case.
26. Shift rail spring to the shift rail.
27. Clutch coil to the rear case. Tighten
28. Clutch coil nuts to the clutch coil.
• Bolts to 41 N.m (30 lbs. ft.).
$ Tighten
3. Four-wheel drive indicator switch to the front case
half.
• Clutch coil nuts to 10 N.m (84 lbs. in.).
29. Clutch coil wire through the rear case and clutch & Tighten
coil wire connector to the clutch coil wire (figure 4).
30. RTV sealer (GM P/N 12345739) or the equivalent • Switch to 27 N m (20 lbs. ft.).
to the pump body sealing surfaces and the front 4. Speed sensor and bolt to the rear bearing retainer.
and rear case halves.
31. Case screws to the case halves. a Tighten
Tighten Tighten
• Nut to 170 N.m (125 lbs. ft.). Nut to 224 N.m (165 lbs. ft.).
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N-m Lbs. Ft. Lbs. In.
Case and Rear Bearing Retainer Screws..................................... ........................ 41 30 —
Clutch Coil Nuts............................................................................ ........................ 10 — 84
Drain/Fill Plugs............................................................................... ........................ 25 18 —
Yoke Nut (Front Output)................................................................ ........................ 224 165 —
Four Wheel Drive Indicator Switch............................................. ........................ 20 27 —
P.T.O. Cover Bolts......................................................................... .......................... 27 20 —
Pump Cover Screws............................................................................. .......................... 2.5 - 22
Speed Sensor Bolt................................................................................ ........................ 16 12 —
........................ 14 10 —
Yoke Nut (Rear Output)................................................................ ........................ 170 125 —
LUBRICATION SPECIFICATIONS
Capacity................................................................................................................................................................... 3.1L (3.3 qts.)
Type Recommended............................................................................................Dexron® III Automatic Transmission Fluid
T2689
7D6-10 BORG-WARNER 4470 TRANSFER CASE
SPECIAL TOOLS
1. J 22912-01
6. J 8092
2. J 8433-4 7. J 5590
8. J 29369-1
3. J 29169
9. J 2619-01
4. J 33832
V1192
INDEX-1
Cleaning and Inspection
A Engine (5.0L, 5.7L, and 7.4L).........................6A5B-34
Engine (Diesel).....................................................6A7-23
ABS Sensor Ring Replacement
Rear Axle (Locking Differential)........................... 4B7-3
Front Axle (7 1/4 Inch Ring Gear
Transfer Case (BW 4470)....................................7D6-6
and A W D )......................................................... 4C2-17
Transfer Case (BW 4472)....................................7D5-6
Front Axle (8 1/4 and 9 1/4-Inch
Transfer Case (NP 231).....................................7D3-10
Ring Gear)........................................................ 4C2-17
Transfer Case (NP 241).......................................7D2-7
Air Conditioning Compressor (HD6/HR6-HE)....... 1D2-1
Transfer Case (NP 233).....................................7D1-10
Axle Actuator Check, Front Axle
Cleaning and Inspection, and Electrical Tests
(8 1/4 and 9 1/4-Inch Ring G ea r).......................4C2-7
(SD210/260)......................................................... 6D2A-4
Axle and Differential Assembly, Front Axle
Cleaning and Inspection, and Repair (28-MT).... 6D2B-6
7 1/4 Inch Ring Gear and A W D .........................4C2-9
Component Electrical Testing (28-MT)................ 6D2B-7
8 1/4 and 9 1/4-Inch Ring Gear..........................4C2-8
Connecting Rod and Piston Installation
Axle and Differential Assembly, Rear Axle
(Diesel)...................................................................6A7-28
7 5/8 inch Ring Gear............................................ 4B1-7
Connecting Rod Bearing Selection
8 1/2 and 8 5/8 Inch Ring G ear.........................4B2-6
(4.3L VIN W )...................................................... 6A4B-29
9 1/2 inch Ring Gear............................................ 4B3-6
Connecting Rod Bearing Selection
10 1/2 inch Ring Gear.......................................... 4B4-2
(4.3L VIN Z )....................................................... 6A3B-28
11 inch Ring Gear................................................. 4B5-2
Connecting Rod Bearing Selection
Axle Disassembly, Front Axle
(5.0L, 5.7L, and 7.4L)......................................6A5B-42
7 1/4 Inch Ring Gear and A W D .........................4C2-2
Connecting Rod Bearings (Diesel)........................6A7-28
8 1/4 and 9 1/4-Inch Ring Gear..........................4C2-2
Coolant Crossover Removal (Diesel)..................... 6A7-7
Axle Disassembly, Rear Axle.................................. 4B1-2
Coolant Pump Removal
7 5/8 inch Ring Gear............................................ 4B1-2
4.3L VIN W .......................................................... 6A4B-9
8 1/2 and 8 5/8 Inch Ring G ear.........................4B2-2
4.3L VIN Z ........................................................... 6A3B-9
9 1/2 inch Ring Gear............................................ 4B3-2
5.0L, 5.7L, and 7.4L......................................... 6A5B-14
10 1/2 inch Ring Gear.......................................... 4B4-2
Diesel....................................................................... 6A7-9
11 inch Ring G ear.................................................4B5-2
Countershaft................................................................7B8-7
Crankshaft and Bearings
B 4.3L VIN W ........................................................ 6A4B-23
Backlash Adjustment, Front Axle 4.3L VIN Z )........................................................ 6A3B-23
7 1/4 Inch Ring Gear and A W D .......................4C2-12 5.0L, 5.7L, and 7.4L......................................... 6A5B-37
8 1/4 and 9 1/4-Inch Ring Gear........................4C2-13 Diesel..................................................................... 6A7-23
Backlash Adjustment, Rear Axle Crankshaft Position Sensor................................ 6D4B1-2
7 5/8 inch Ring Gear.......................................... 4B1-11 Crankshaft Oil Seal Retainer
8 1/2 and 8 5/8 Inch Ring G ear.......................4B2-10 4.3L VIN W ........................................................ 6A4B-14
9 1/2 inch Ring Gear.......................................... 4B3-10 4.3L VIN Z ......................................................... 6A3B-13
10 1/2 inch Ring Gear.......................................... 4B4-8 5.0L and 5.7L....................................................6A5B-38
11 inch Ring G ear)............................................. 4B5-13 Crankshaft Removal
Block, Cylinder (Diesel).......................................... 6A7-13 4.3L VIN W .................................................... . 6A4B-15
Booster Assembly......................................................5D1-1 4.3L VIN Z ......................................................... 6A3B-13
Booster (Hydraulic) Repair.......................................5D3-1 5.0L, 5.7L, and 7.4L ....................................... 6A5B-21
Booster (Vacuum) Repair......................................... 5D2-1 Diesel..................................................................... 6A7-12
Crankshaft Sprocket Replacement
c 4.3L VIN W ........................................................ 6A4B-19
Camshaft 4.3L VIN Z ......................................................... 6A3B-18
4.3L VIN W ........................................................... 6A4B-3 5.0L, 5.7L, and 7.4L......................................... 6A5B-29
4.3L VIN Z .......................................................... 6A3B-18 C/V Joint Outer Joint Assembly Replacement
5.0L, 5.7L, and 7 .4 L ......................................... 6A5B-29 (8 1/4 and 9 1/4-Inch Ring Gear).....................4C2-20
Diesel.....................................................................6A7-16 C/V Joint Outer Seal Replacement
Chatter Test (Diesel)............................................... 6A7-23 (8 1/4 and 9 1/4-Inch Ring Gear)............... 4C2-18
Checking Backlash, Rear Axle Cylinder Block
(11 inch Ring Gear).............................................4B5-12 4.3L VIN Z ......................................................... 6A3B-15
Checking Axle Before Disassembly 4.3L VIN W .......................................................... 6A4B-3
(7 5/8 Inch Ring G ear)......................................... 4B1-2 5.0L, 5.7L, and 7.4L......................................... 6A5B-26
(9 1/2 Inch Ring G ear).........................................4B3-2 Cylinder Bore
(10 1/2 Inch Ring G ear).......................................4B4-2 4.3L VIN Z ...................................................... 6A3B16
(11 Inch Ring G ear).............................................. 4B5-2 4.3L VIN W ........................................................ 6A4B-17
Cleaning 5.0L, 5.7L, and 7.4L......................................... 6A5B-28
7 5/8 Inch Ring Gear............................................ 4B1-4 Diesel..................................................................... 6A7-13
8 1/2 and 8 5/8 Inch Ring G ear.........................4B2-4 Cylinder Bore Reconditioning
9 1/2 Inch Ring Gear............................................ 4B3-5 2.2L Engines............................................................. 6A-3
10 1/2 Inch Ring Gear...... ................................... 4B4-5 All Except 2.2L Engines......................................... 6A-4
11 Inch Ring G e a r................................................ 4B5-6 Diesel..................................................................... 6A7-14
INDEX-2
Cylinder Heads E
4.3L VIN W ........................................................... 6A4B-3
5.0L, 5.7L, and 7 .4 L ......................................... 6A5B-33 Engine
Diesel..................................................................... 6A7-20 2.2L L4 (VIN 4 ) ...................................................6A2B-1
Cylinder Head Disassembly 4.3L V6 Engine (VIN W )....................................6A4B-1
4.3L VIN W ......................................................... 6A4B-21 4.3L V6 Engine (VIN Z ) .....................................6A3B-1
4.3L VIN Z .......................................................... 6A3B-21 Diesel Engines....................................................6A7B-1
Cylinder Head Removal V8Engines............................................................ 6A5B-1
4.3L VIN Z .......................................................... 6A3B-10 Engine Accessory Removal
4.3L VIN W ......................................................... 6A4B-10 Diesel....................................................................... 6A7-4
5.0L, 5.7L, and 7 .4 L ......................................... 6A5B-16
4.3L (VIN W ) ....................................................... 6A4B-8
Diesel....................................................................... 6A7-8
4.3L (VIN Z)......................................................... 6A3B-8
5.0L, 5.7L, and 7.4L......................................... 6A5B-13
D Diesel....................................................................... 6A7-4
Distributors...............................................................6D4A-1 Engine Identification Number.....................................OA-3
Diagnosis, Starter (28-M T)................................... 6D2B-2 Engine Identification (5.0L, 5.7L, and 7.4L )...... 6A5B-3
Diagnosis, Starter (SD210 /2 6 0 )...........................6D2A-2
Engine Lubrication
Differential
4.3L VIN Z ........................................................... 6A3B-3
Adjustments, Tooth Contact
4.3L VIN W .......................................................... 6A4B-3
Front Axle
(7 1/4 Inch Ring Gear and AWD)............. 4C2-14 Diesel....................................................................... 6A7-3
Front Axle Engine Setup and Testing
(8 1/4 and 9 1/4-Inch Ring Gear)............. 4C2-13 4.3L VIN Z ......................................................... 6A3B-35
Rear Axle (10 1/2 inch Ring G ear)................ 4B4-9 5.0L, 5.7L, and 7.4L......................................... 6A5B-53
Rear Axle (11 inch Ring Gear)..................... 4B5-13 Diesel..................................................................... 6A7-38
Rear Axle (7 5/8 inch Ring G ear)................ 4B1-12 4.3L VIN W ........................................................ 6A4B-35
Rear Axle EGR Valve Removal
(8 1/2 and 8 5/8 inch Ring Gear)............. 4B2-13 4.3L VIN W .......................................................... 6A3B-9
Rear Axle (9 1/2 inch Ring G ear)................ 4B3-11 4.3L VIN Z ........................................................... 6A4B-9
Rear Axle (Locking Differential).......................4B7-4 Exhaust Manifold Removal
Final Assembly 4.3L VIN W .......................................................... 6A4B-9
Front Axle 4.3L VIN Z ........................................................... 6A3B-9
(7 1/4 Inch Ring Gear and AW D).............4C2-14 5.0L, 5.7L, and 7.4L......................................... 6A5B-14
Front Axle (8 1/4 and 9 1/4-Inch Ring Gear), Diesel....................................................................... 6A7-6
Rear Axle (7 5/8 inch Ring G ear)................ 4B1-12
Rear Axle
(8 1/2 and 8 5/8 inch Ring Gear).............4B2-13 F
Rear Axle (9 1/2 inch Ring G ear)................ 4B3-11 Flywheel Removal
Rear Axle (10 1/2 inch Ring G ear)................ 4B4-9 4.3L VIN W ......................................................... 6A4B-11
Rear Axle (11 inch Ring Gear)..................... 4B5-13 4.3L VIN Z ......................................................... 6A3B-12
Gear Tooth Nomenclature
5.0L, 5.7L, and 7.4L......................................... 6A5B-21
Front Axle
Diesel....................................................................... 6A7-4
(7 1/4 Inch Ring Gear and AWD).............4C2-13
Front Cover Removal
Rear Axle (11 inch Ring Gear)..................... 4B5-13
Rear Axle (9 1/2 inch Ring G ear)................ 4B3-10 Diesel..................................................................... 6A7-10
Rear Axle (7 5/8 inch Ring G ear)................ 4B1-12 4.3L VIN Z ......................................................... 6A3B-12
Rear Axle (10 1/2 inch Ring G ear)................ 4B4-9 4.3L VIN W ......................................................... 6A4B-11
Gear Tooth Pattern Check 5.0L, 5.7L, and 7.4L....................................... ..6A5B-17
Front Axle
(8 1/4 and 9 1/4-Inch Ring Gear)............. 4C2-13 . . . ■ ©
Front Axle
(7 1/4 Inch Ring Gear and AWD).............4C2-13 Generator (CS-144)................................................6D3A-1
Rear Axle Generator Output Test........................................... 6D3A-2
(8 1/2 and 8 5/8 inch Ring Gear).............4B2-11 Glow Plug Removal..................................................6A7-6
Rear Axle (9 1/2 inch Ring G ear)................ 4B3-10
Rear Axle (10 1/2 inch Ring G ear)................ 4B4-9 H
Rear Axle (11 inch Ring Gear)..................... 4B5-13
Rear Axle (7 5/8 inch Ring G ear)................ 4B1-12 High Voltage Switch............................................. 6D4B1-1
Differential Cam Unit Assembly (All Except Hydraulic Lifters
9 1/2-lnch Rear Axle) (Locking Differential)..... 4B7-4 4.3L VIN Z ..............................................................6A3B-
Differential Cam Unit Disassembly (9 1/2-lnch) 5.0L, 5.7L, and 7.4L......................................... 6A5B-33
Rear Axle (Locking Differential)...........................4B7-3 4.3L VIN W ........................................................ 6A4B-21
Dipstick Tube Removal (Diesel)...................... .......6A7-6 Diesel..................................................................... 6A7-19
INDEX-3
I P
Ignition Control Module.........................................6D4A-1 Piston and Connecting Rod Assemblies................. 6A-5
Ignition Coil............................................................. 6D4A-1 Pinion Assembly, Rear Axle
Ignition Coil Test...................................................6D4B1-3 (10 1/2-Inch Ring G ear)........................................ 4B4-6
Ignition Coil/Coil Driver........................................6D4B1-1 Pinion Bearing Preload Specification, Rear Axle
Injection Line Removal (Diesel).............................. 6A7-4 (11-Inch Ring Gear)............................................. 4B5-15
Injection Nozzle Tests (Diesel).............................. 6A7-22 Pinion Bearing Cup Installation, Front Axle
Injection Nozzle Tests (Diesel).............................. 6A7-22 7 1/4-Inch Ring Gear and AW D......................... 4C2-9
Injection Nozzle Removal (Diesel)..........................6A7-5 8 1/4 and 9 1/4-Inch Ring Gear......................... 4C2-8
Injection Pump Removal (Diesel).........................6A7-10 Pinion Clearance Check (SD210/260)................ 6D2A-7
Injection Pump Repair (Diesel)............................. 6A7-23 Pinion Depth Adjustment
Intake Manifold Front Axle
4.3L VIN W ........................................................... 6A3B-9 (7 1/4-Inch Ring Gear and AW D)................ 4C2-10
4.3L VIN Z ............................................................ 6A4B-9 Front Axle
Diesel....................................................................... 6A7-4 (8 1/4 and 9 1/4-Inch Ring Gear)...................4C2-9
5.0L, 5.7L, and 7.4L ......................................... 6A5B-29 Rear Axle (7 5/8-Inch Ring G ear).......................4B1-7
Rear Axle (8 1/2 and 8 5/8-Inch Ring Gear).... 4B2-7
L Rear Axle (9 1/2-Inch Ring G ear).......................4B3-6
Rear Axle (11-Inch Ring Gear)............................ 4B5-9
Leakage Test (Diesel)............................................. 6A7-22
Locking Differentials................................................. 4B7-2 Pinion Installation
Lubrication Front Axle
Front Axle (7 1/4-Inch Ring Gear and AW D)................. 4C2-11
(7 1/4 Inch Ring Gear and AWD)................. 4C2-23 Front Axle
Front Axle (8 1/4 and 9 1/4-Inch Ring Gear)................ 4C2-10
(8 1/4 and 9 1/4-1 nch Ring Gear)................. 4C2-23 Rear Axle (7 5/8-Inch Ring G ear).....................4B1-10
Rear Axle (Locking Differential).........................4B7-10 Rear Axle (8 1/2 and 8 5/8-Inch Ring Gear).... 4B2-8
Rear Axle (7 5/8 inch Ring Gear).................... 4B1-15 Rear Axle (9 1/2-Inch Ring G ear).......................4B3-7
Rear Axle Rear Axle (10 1/2-Inch Ring G ear).....................4B4-7
(8 1/2 and 8 5/8 inch Ring Gear)................. 4B2-14 Rear Axle (11-Inch Ring Gear).......................... 4B5-10
Rear Axle (9 1/2 inch Ring Gear).................... 4B3-14 Pinion Preload and Backlash, Front Axle
Rear Axle (10 1/2 inch Ring Gear).................. 4B4-11 7 1/4-Inch Ring Gear and AW D.......................4C2-23
Rear Axle (11 inch Ring G ea r).........................4B5-15 8 1/4 and 9 1/4-Inch Ring Gear.......................4C2-23
Piston and Connecting Rod Removal
M 4.3L VIN W ........................................................ 6A4B-13
5.0L, 5.7L, and 7.4L ............................................ 6A5B-19
Master Cylinders.......................................................... 5A-2 Diesel..................................................................... 6A7-11
Master Cylinder Booster Assembly.........................5D1-1 Piston Selection
Master Cylinder Gaging Procedure.........................5D1-6 2.2L Engines..............................................................6A-6
5.0L, 5.7L, and 7.4L......................................... 6A5B-28
o Diesel..................................................................... 6A7-15
Piston and Connecting Rod Installation
Oil Filler Neck Removal (Diesel)............................ 6A7-6
4.3L VIN W ........................................................ 6A4B-29
Oil Filter Bypass Valve and
4.3L VIN Z ......................................................... 6A3B-28
Block Plug (Diesel)............................................. 6A7-13
5.0L, 5.7L, and 7.4L......................................... 6A5B-42
Oil Pan Removal
Piston and Connecting Rod Assembly
4.3L VIN Z .......................................................... 6A3B-11
5.0L, 5.7L, and 7.4L......................................... 6A5B-28
4.3L VIN W ......................................................... 6A4B-11
4.3L VIN W ........................................................ 6A4B-17
5.0L, 5.7L, and 7 .4 L ......................................... 6A5B-16
Diesel.....................................................................6A7-11 4.3L VIN Z ......................................................... 6A3B-17
Oil Pan and Rocker Arm Covers Diesel..................................................................... 6A7-14
5.0L, 5.7L, and 7 .4 L ......................................... 6A5B-31 Piston Measurement (Diesel)................................ 6A7-14
4.3L VIN W ......................................................... 6A4B-20 Piston and Connecting Rod Removal
4.3L VIN Z .......................................................... 6A3B-19 (4.3L VIN Z )....................................................... 6A3B-13
Diesel.....................................................................6A7-18 Pistons and Connecting Rods (4.3L VIN W).... 6A4B-33
Oil Pump Removal Pole Piece and Coil Assembly............................. 6D4A-2
4.3L VIN Z .......................................................... 6A3B-12 Power Flow
5.0L, 5.7L, and 7.4L .........................................6A5B-16 NP231..................................................................... 7D3-1
4.3L VIN W .........................................................6A4B-11 NP233..................................................................... 7D1-3
Diesel.....................................................................6A7-11 NP241..................................................................... 7D2-1
Opening Pressure Test (Diesel)............................6A7-22 BW4401 ..................................................................7D4-1
Oversize Rear Main Bearing Thrust Faces BW 4470..................................................................7D6-1
(5.0L and 5.7L).................................................. 6A5B-38 BW 4472..................................................................7D5-1
INDEX-4
Pushrod and Rocker Arm Installation Side Bearing Preload Adjustment
(Diesel)..................................................................6A7-32 Rear Axle (10 1/2-Inch Ring G ear).................... 4B4-8
Pushrods, Rocker Arms, Balls, and Nuts Rear Axle (9 1/2-Inch Ring G ear)...................... 4B3-9
4.3L VIN Z ..........................................................6A3B-21 Rear Axle (8 1/2 and 8 5/8-Inch Ring Gear).... 4B2-9
4.3L VIN W ................... ..................................... 6A4B-21 Rear Axle (7 5/8-Inch Ring G ear)...................... 4B1-9
5.0L, 5.7L, and 7 .4 L .........................................6A5B-33 Slip Ring End Frame............................................. 6D3A-3
Reaction Block Size - 10 1/2-Inch, Rear Axle Solenoid Switches (28-M T)................................ 6D2B-12
(Locking Differential)...... ..................................... 4B7-10 Solenoid Switches (SD210/260)...........................6D2A-8
Reaction Block Thrust Washers, Rear Axle Solenoid (SD210/260)............................................ 6D2A-3
(Locking Differential)............................................4B7-10 Spacer and Shim Specifications
Reaming Valve Guides.............................................6A-12 Rear Axle (7 5/8-Inch Ring G ear).................... 4B1-15
Rear Axle (8 1/2 and 8 5/8-Inch Ring Gear)....... 4B2-1 Rear Axle (10 1/2-Inch Ring G ear).................. 4B4-11
Rear Axle (7 5/8-Inch Ring G ear)..........................4B1-1 Rear Axle
Rear Crankshaft Oil Seal Installation (Diesel) ....6A7-38 (8 1/2 and 8 5/8-Inch Ring Gear).. 4B2-14,.4b2-14
Rear Crankshaft Seal Removal (Diesel).............6A7-12 Rear Axle (9 1/2-Inch Ring G ear).................... 4B3-14
Rear Housing Special Tool Ordering Information............................. 0A-1
Disassembly........................................................... 7B7-8 Special Tools
Assembly.............................................................. 7B7-14 Front Axle
Rear Oil Retainer Extension Housing.................... 7B8-8 (7 1/4-Inch Ring Gear and AW D)................ 4C2-24
Rectifier Bridge Test.............................................. 6D3A-5 Front Axle
Regulator..................................................................6D3A-6 (8 1/4 and 9 1/4-Inch Ring Gear)................ 4C2-24
Repair Procedures (28-MT).................................. 6D2B-8 Rear Axle (7 5/8-Inch Ring G ear).................... 4B1-16
Replacing Engine Gaskets.........................................6A-2 Rear Axle
Return Line Removal (Diesel)................................. 6A7-5
(8 1/2 and 8 5/8-Inch Ring Gear)................. 4B2-15
Return Line Installation (Diesel)............................6A7-36
Rear Axle (9 1/2-Inch Ring G ear).................... 4B3-15
Reverse Idler G ear................................................. 7B7-12
Rear Axle (11-Inch Ring Gear)..........................4B5-16
Disassembly........................................................... 7B7-7
Rear Axle (10 1/2-Inch Ring G ear).................. 4B4-12
Assembly.............................................................. 7B7-15
Rear Axle (Locking Differential).........................4B7-11
Right Side Gear Thrust Washer, Rear Axle
Specifications
(Locking Differential)............................................ 4B7-10
28-MT Starter....................................................6D2B-12
Ring Gear Bolts, Rear Axle
SD210/260 Starter.............................................. 6D2A-8
(11-Inch Ring G ear)............................................ 4B5-15
CS-144 Generator.............................................. 6D3A-8
Rocker Arm and Pushrod Removal (Diesel).........6A7-8
Front Axle
Rocker Arm Cover Installation
(8 1/4 and 9 1/4-Inch Ring Gear)................ 4C2-23
4.3L VIN W ......................................................... 6A4B-33
Rear Axle (7 5/8-Inch Ring G ear).................... 4B1-15
4.3L VIN Z .......................................................... 6A3B-33
Rear Axle
5.0L, 5.7L, and 7 .4 L .........................................6A5B-49
(8 1/2 and 8 5/8-Inch Ring Gear)................. 4B2-14
Diesel.....................................................................6A7-32
Rear Axle (9 1/2-Inch Ring Gear).................... 4B3-14
Rocker Arm Cover Removal
Rear Axle (10 1/2-Inch Ring G ear)...... ........... 4B4-11
4.3L VIN Z ................ ........................................... 6A3B-9
Rear Axle (11-Inch Ring Gear)..........................4B5-15
4.3L VIN W ........................................................... 6A4B-9
Rear Axle (Locking Differential).........................4B7-10
5.0L, 5.7L, and 7.4L...........................................6A5B-14
Sanden A/C Compressor.....................................1D4-4
Diesel....................................................................... 6A7-7
Spray Test (Diesel)..................................................6A7-23
Rocker Arm Stud Replacement
Starter (SD210/260)............................................... 6D2A-8
4.3L VIN Z ..........................................................6A3B-22
Starter (28-MT)........................................................ 6D2B-1
4.3L VIN W ......................................................... 6A4B-22
Starter (28-MT) Diagnosis.....................................6D2B-2
5.0L and 5.7L Engines.....................................6A5B-34
Rotor Field Winding Tests.....................................6D3A-5 Starter (SD210/260) Diagnosis............................. 6D2A-2
Rough Honing (Diesel)........................................... 6A7-14 Starter Motor Tests (SD210/260).........................6D2A-2
RTV Sealer and Anaerobic Gasket Eliminator........6A-2 Statement on Cleanliness and Care.........................6A-2
Stator Test................................................................6D3A-5
Synchronizer Assembly (BW 4 4 7 0 )....................... 7D6-7
s Synchronizer Assembly.......................................... 7B7-15
Sanden SD-7H15 Air Synchronizer Assembly........................................... 7D6-7
Conditioning Compressor......................................1D4-1 Synchronizer Blocker Rings.....................................7B6-8
SD Starter Motors.................................................. 6D2A-1 Synchronizer Disassembly..... ......................... ........ 7B7-6
Secondary W ires................................................. 6D4B1-2 Synchronizer Hub Assembly (BW 4 401)...... ....... 7D4-7
Service Parts Identification Label............................. 0A-1 Synchronizer Hub Assembly.................................. 7D6-5
Shift Cover..................................................................7B8-9 Synchronizer Hub Assembly.................................. 7D4-4
Shim Pack Size, Rear Axle Synchronizer Hub Assembly (BW 4 470).............. 7D6-5
(11 Inch Ring Gear).............................................. 4B5-8 Synchronizer Hub Assembly (BW 4 401).............. 7D4-4
Shift Lever Housing................................................ 7B7-13 Synchronizer Hub Assembly.................................. 7D4-7
Shift Shaft/Rail and Fork Assemblies.................. 7B7-12 Synchronizer Keys and Springs.............................. 7B6-9
INDEX-5
Borg-Wagner 4470 Transfer Case......................7D6-1
T Borg-Wagner 4472 Transfer Case......................7D5-1
TDC on the Front Cover (Diesel).........................6A7-29 New Process 231..................................................7D3-1
Test, Front Axle New Process 233.................................................. 7D1-1
(7 1/4-Inch Ring Gear and A W D ).................... 4C2-13 New Process 24 1 ..................................................7D2-1
Test, Front Axle Transmission C ase....................................................7B6-7
(8 1/4 and 9 1/4-Inch Ring G ear).................... 4C2-13 Transmission Identification Number..........................OA-3
Testing After Overhaul (28-MT)..........................6D2B-12 Transmission Disassembly.......................................7B7-2
Thermostat and Coolant Outlet Transmission Disassembly.......................................7B6-3
4.3L VIN W ......................................................... 6A4B-23 Transmission Cover.................................................7B6-10
4.3L VIN Z .......................................................... 6A3B-23
5.0L, 5.7L, and 7 .4 L .........................................6A5B-36
Thermostat and Coolant Crossover (Diesel)...... 6A7-21
u
Thermostat Housing Removal (Diesel).................. 6A7-6 Undersize Main Journals
Thread Repair............................................................ 6A-15 (5.0L and 5.7L Engines)................................. 6A5B-38
Thrust Block Sizes, Rear Axle Upper and Lower Intake and
(Locking Differential)........................................... 4B7-10 Exhaust Manifolds (4.3L VIN W )....................6A4B-18
Timing Chain and Camshaft Sprocket Removal Upper and Lower Intake and
4.3L VIN W ......................................................... 6A4B-12 Exhaust Manifolds (4.3L VIN Z ) .................... 6A3B-17
4.3L VIN Z .......................................................... 6A3B-12 Upper Intake Manifold Removal
Diesel..................................................................... 6A7-10 (4.3L VIN Z )......................................................... 6A3B-9
Timing Chain and Sprockets Upper Intake Manifold Removal
4.3L VIN Z .......................................................... 6A3B-18 (4.3L VIN W )........................................................ 6A4B-9
4.3L VIN W ......................................................... 6A4B-18
5.0L, 5.7L, and 7.4L ......................................... 6A5B-29 V
Timing Chain Removal
(5.0L, 5.7L, and 7.4L).......................................6A5B-17 V-5 Air Conditioning Compressor........................... 1D3-1
Timing Chain, Sprockets, V8 Engines...............................................................6A5B-1
and Timing Gears (Diesel)................................ 6A7-18 Vacuum Booster Repair........................................... 5D2-1
Torsional Damper Valve Adjustment
4.3L VIN Z .......................................................... 6A3B-23 (5.0L, 5.7L, and 7.4L).....................................6A5B-46
4.3L VIN W ......................................................... 6A4B-23 Valve Grinding............................................................ 6A--12
5.0L, 5.7L, and 7 .4 L .........................................6A5B-37 Valve Lifter Leakdown Rate Test
Diesel..................................................................... 6A7-24 (Flat Type Lifters Only).......................................... 6A-10
Torsional Damper Removal Valve Train Components
Diesel....................................................................... 6A7-9 4.3L VIN W ........................................................ 6A4B-21
5.0L, 5.7L, and 7 .4 L ......................................... 6A5B-16 4.3L VIN Z ......................................................... 6A3B-19
4.3L VIN W ......................................................... 6A4B-11 5.0L, 5.7L, and 7.4L......................................... 6A5B-14
4.3L VIN Z ............................................................ 6A3B-9 Diesel..... ............................................................... 6A7-19
Transfer Case Vehicle Certification Label.......................................... OA-2
Borg-Wagner 4401 Transfer C a s e ..................... 7D4-1 Vehicle Identification Number.....................................OA-2
INDEX-6
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