GMT 95 LUR 1995 GM Light Duty Truck Unit Repair Manual PDF

CAUTION
To reduce the chance of personal injury and/or property damage, the

following instructions must be carefully observed:
Proper service and repair are important to the safety of the service
technician and the safe, reliable operation of all motor vehicles. If part
replacement is necessary, the part must be replaced with one of the
same part number or with an equivalent part. Do not use a replacement
part of iesser quality.
The service procedures recommended and described in this service

manual are effective methods of performing service and repair. Some
of these procedures require the use of tools specifically designed for
the purpose.
Accordingly, anyone who intends to use a replacement part, service

p ro c ed u re , or tool that is not recom m ended by the v eh ic le
manufacturer must first determine that neither his safety nor the safe
operation of the vehicle will be jeopardized by the replacement part,
service procedure, or tool selected.
It is important to note that this manual contains various ‘Cautions’ and

‘Notices’ that must be carefully observed in order to reduce the risk of
personal injury during service or repair, or the possibility that improper
service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ‘Cautions’ and ‘Notices’ are not
exhaustive, because it is impossible to warn of all the possible
hazardous consequences that might result from failure to follow these
instructions.
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.
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.
General Motors Corporation

Pontiac, Michigan
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.
SECTION SUBJECT CONTENTS

A GENERAL OA GENERAL INFORMATION
u
INFORMATION
AIR 1D1 HR100T/HR110MD AIR 1D3 V-5 AIR CONDITIONING
4 CONDITIONING CONDITIONING COMPRESSOR COMPRESSOR
I
1D2 HD6/HR6-HE AIR 1D4 SD-7H15 AIR CONDITIONING
CONDITIONING COMPRESSOR COMPRESSOR
o STEERING 3B1A POWER STEERING GEAR UNIT 3B1B POWER STEERING PUMP UNIT
3
REPAIR REPAIR
PROPELLER 4B REAR AXLE 4B7 LOCKING DIFFERENTIAL
SHAFT AND 4B1 7 5/8-INCH RING GEAR 4C1 7 1/4-INCH RING GEAR AND
AXLES 4B2 8 1/2 AND 8 5/8-INCH RING ALL WHEEL DRIVE FRONT
GEAR AXLE
4A
4B3 9 1/2-INCH RING GEAR 4C2 8 1/4 AND 9 1/4-INCH RING
4B4 10 1/2-INCH RING GEAR GEAR
4B5 DANA MODEL 80 (11-INCH
RING GEAR)
BRAKES 5A1 MASTER CYLINDER 5D3 HYDRAULIC BOOSTER
5
5D2 VACUUM BOOSTER SYSTEM
ENGINE 6A GENERAL ENGINE 6C1 MODEL 220 TBI UNIT
MECHANICAL 6D ENGINE ELECTRICAL
6A3B 4.3L V6 ENGINE (VIN Z) 6D2A SD STARTER MOTORS
6 6A4B 4.3L V6 ENGINE (VIN W) 6D2B 28-MT STARTER MOTORS
6A5B V8 ENGINES 6D3A CS-144 GENERATOR
6A7 6.5L DIESEL 6D4A DISTRIBUTORS
6D4B1 HIGH VOLTAGE SWITCH
TRANSMISSION 7A14B HYDRA-MATIC 4L60E 7D1 NEW PROCESS 233 TRANSFER
AUTOMATIC TRANSMISSION CASE
UNIT REPAIR 7D2 NEW PROCESS 241 TRANSFER
7A17B HYDRA-MATIC 4L80E CASE
AUTOMATIC TRANSMISSION 7D3 NEW PROCESS 231 TRANSFER
UNIT REPAIR CASE
7 7B6 BORG-WARNER T5 MANUAL 7D4 BORG-WARNER 4401
TRANSMISSION TRANSFER CASE
7B7 NEW VENTURE GEAR NV-3500 7D5 BORG-WARNER 4472
'-'4 MANUAL TRANSMISSION TRANSFER CASE
7B8 NEW VENTURE GEAR 4500 7D6 BORG-WARNER 4470
MANUAL TRANSMISSION TRANSFER CASE
7D TRANSFER CASE
INDEX ALPHABETICAL INDEX
GENERAL MOTORS SERVICE MANUAL COMMENTS
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
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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
SPECIAL TOOL ORDERING • Model year and vehicle line

• Publication part number (if present)
INFORMATION • Vehicle Identification Number of vehicle being
Special service tools shown in this service manual worked on
that have tool product numbers beginning with “J” or • Section and page number(s)
“BT” are available for worldwide distribution from: • Description of problem
Kent-Moore
SPX Corporation This phone number cannot provide technical assis
29784 Little Mack tance. Contact your regular technical assistance source.
Roseville, Ml 48066-2298 The personnel answering this phone number will pro
1-800-345-2233 vide the author of the information with your comments
Mon.-Fri. 8:00 a.m.-5:00 p.m. EST and will follow-up until an answer is given.
Telex: 244040 KMTR VR If you wish to send examples or marked-up pages,
Fax: 810-578-7375 the person who takes your call will tell you how to do
TECH 1 scan tools and accessories can be pur that.
chased through Kent-Moore at the above address
and phone number. United States And Canadian Vehicle
Owner/Operator
GM SERVICE MANUAL If you are the owner or operator of the vehicle, please
COMMENTS give your comments to the applicable Customer Assis
If you find an error, or have a suggestion on any tance Center. The phone number and address are in
General Motors Service Manual, we want to hear from your Owner’s Manual.
you.
United States (General Motors Dealer Employees SERVICE PARTS
Only) IDENTIFICATION LABEL
• 1-800-828-6860
• 8:00 AM— 5:00 PM Eastern Time Zone The service parts identification label is provided on all
models (figure 1). It is located on the inside of the
Canada, French Speaking (General Motors Dealer instrument panel storage compartment (or on an inner
Employees Only) body panel for Forward Control models). The label lists
• 1-800-503-3222 the Vehicle Identification Number (VIN), wheelbase,
• 8:30— 5:00 PM Eastern Time Zone paint information, and all production options or special
These phone numbers can be called Monday through equipment on the vehicle when it was shipped from the
Friday. Be prepared to give the following information: factory. ALWAYS REFER TO THIS INFORMATION
• Your name WHEN ORDERING PARTS.
• Your dealership’s name
• Your phone number
OA-2 GENERAL INFORMATION
□ cm □ izzi tzzi □ □ izzi izzi izzi izzi tzzi c m

d D IZZJ IZZI [ZD IZZI IZZI IZZ3 CZ] CZD HZ] HZ] CZZI IZZ)
c = ] c = ii= ic = 3 c = ] i= ] [= ii= ] c z : i= ic = ] c = ] [ = ii
IZZI IZZI IZZI IZZI IZZI IZZI IZZI
□ c
Figure 2—VIN Location
Figure 1—Service Parts Identification Label VEHICLE CERTIFICATION LABEL

The vehicle certification label shows the Gross Vehi
VEHICLE IDENTIFICATION cle Weight Rating (GVWR), the front and rear Gross
Axle Weight Rating (GAWR), and the payload rating for
NUMBER the vehicle (figure 4).
The VIN is the legal identifier of the vehicle. On all The gross vehicle weight (GVW) is the weight of the
models except Forward Control, it is located on a plate originally equipped vehicle and all items added to it
that is attached to the left top of the instrument panel. It after it has left the factory. This would include bodies,
can be seen through the windshield from the outside of winches, booms, etc., the driver and all occupants, and
the vehicle (figure 2). On Forward Control models, the the load the vehicle is carrying. The gross vehicle
plate is on the cowl panel. To find the manufacturer, weight (GVW) must not exceed the gross vehicle weight
model and chassis type, engine type, GVW range, mod rating (GVWR). Also, the front and rear gross axle
el year, plant code, and sequential number, refer to weights (GAW) must not exceed the front and rear
figure 3. gross axle weight rating (GAWR).
VEHICLE IDENTIFICATION NUMBER (VIN)

2 1 K 8 1 1
XI r . H Production Sequence Number
Nation of Origin Code Series Check Digit
1 = US Built 1 1/2 Ton
2 - Canadian Built A s s e m b ly P lant
2 314 Ton
Code Year B Baltim ore. MD
3 1 Ton
S 1995 E Pontiac, Ml
Manufacturers J Janesville, Wi
G=General Motors Code Body Type Z Fort W ayne, Ind.
1 Hi-C ube/Cutaw ay Van
1 O shaw a, ON
C ode M ake 2 Forward Control
2 M oraine, OH
A C hevrolet Bus* 3 Four-D oor Cab
B C hevrolet Incom plete 4 Tw o-Door Cab 3 Detroit. Ml
C Chevrolet Truck 5 Van 4 S c a rb o ro u g h , ON
D G M C Incomplete 6 Suburban 7 Lordstown, OH
J G M C Bus* 7 Motor Hom e Chassis 8 Shreveport, LA
K GMC MPV 8 Utility
N C hevrolet M P V 9 Extended Cab/Van
T G M C Truck
* Van with 4th Seat Engine Type and Make
Line and Chassis Type C ode P ro d u ce r Type RPO
Chassis
GVWR/BRAKE SYSTEM Code Line 4 CPC 2.2 L L4 MFI LN2
Typo
Code GVWR Range Brake System C Conventional Cab 4x2 F CP C 6.5L V 8 Diesel L65
B 3 00 1 -4 0 0 0 Hydraulic D M ilitary Truck 4x4 H CPC 5.0 L V 8 E FI L03
C 4 00 1 -5 0 0 0 Hydraulic K Conventional Cab 4x4 K CPC 5.7 L V 8 E FI L05
D 5 00 1-60 0 0 Hydraulic G Van 4x2 N CPC 7.4 L V 4 E FI L19
E 6 00 1-70 0 0 Hydraulic P Forward Control 4x2 P CPC 6 .5 L V8 D iesel L49
F 7 00 1-80 0 0 Hydraulic S Sm Conventional Cab 4x2
S CPC 6 .5 L V8 D iesel L56
G 8 00 1 -9 ,0 0 0 Hydraulic T Sm Conventional Cab 4x4
H 9 ,0 0 1 -1 0 ,0 0 0 Hydraulic
w CPC 4 3L V 6 C P I L35
M Sm Van 4x2
J 1 0 ,0 01 -1 4,0 00 Hydraulic Y CPC 6 .5 L V8 Diesel L57
L Sm Van 4x4
K 1 4 ,0 0 1 -1 6 ,0 0 0 Hydraulic H Chassis Cutaw ay 4x2 z CPC 4 .3 L V 6 EFI LB4
Figure 3—Vehicle Identification Number

HU
GAWR FRT
LB/K G
SPEED
RTG PSI/K PA (COLD)
□
□
CD
SEE OWNER'S MANUAL FOR ADDIT ION AL INFORMATION
Figure 4—Vehicle Certification Label Figure 5—2.2L Engine I.D. Location
The payload rating shown on the label is the maxi

mum allowable cargo load (including the weight of the
driver and all occupants) that the vehicle can carry
based on all factory installed equipment on the vehicle.
The payload rating is reduced if any accessories or
other equipment is added to the vehicle after final date
of manufacture. The weight of these items should be
determined and deducted from the payload rating.
The vehicle may also have a Gross Combination
Weight Rating (GCWR). The GCW is the total weight of
the loaded tow vehicle (including passengers) and a
loaded trailer.
The tires on the vehicle must be the proper size and
properly inflated for the load which the vehicle is carry
ing. The vehicle certification label shows the original-
ly-equipped tire size and recommended inflation
pressures.
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.
Figure 7—5.0L, 5.7L Engine I.D. Location Figure 8—7.4L Engine I.D. Location
VIEW B
1. Engine I.D. Location VIEW C

F7554
Figure 9—6.5L Diesel Engine I.D. Location

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.
BUILD DAY OF MONTH

MODEL YEAR 0 1 -1 S T DAY
15 - 15TH DAY 1. TRANSMISSION l.D. LOCATION
2. TRANSMISSION IDENTIFICATION TAG
r
~P~[
£
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
Figure 11—New Venture Gear 3500 Transmission I. D. Location

VIEW A
1. TRANSMISSION I.D. LOCATION

V2371
Figure 12—New Venture Gear 4500 Transmission i. D. Location

2. Bolts and nuts which are rusty or damaged should
be replaced with new parts of equal or greater
strength.
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
MODEL YEAR IjU L IA N tX T E I

(94 = 1994) YEAR
HYDRA-MATIC 4L80-E/4L80-EHD TRANSMISSION IDENTIFICATION INFORMATION 3100r4921

YPSILANTI, MICHIGAN
Figure 14—Hydra-Matic 4L80-E Transmission I. D. Location

J1930 CONVERSION CHART

From To
Absolute Pressure Sensor (APS) Manifold Absolute Pressure Sensor (MAP Sensor)
Accelerator (ACCEL) Accelerator Pedal (AP)
Air Cleaner Assembly Air Cleaner (ACL)
Air Cleaner Filter Element Air Cleaner Filter (ACL Filter)
Air Induction System Air Intake System
Air Injection Reaction System (A.I.R. System) Secondary Air Injection System (AIR System)
Assembly Line Communication Link (ALCL) Data Link Connector (DLC)
Assembly Line Data Link (ALDL) Data Link Connector (DLC)
BCM-PCM Data Problem BCM-PCM Data Link
Calibration Pack (CAL-PAK) 1. Electronically Erasable Programmable Read Only
Memory (EEPROM)
2. Erasable Programmable Read Only Memory
(EPROM)
3. Programmable Read Only Memory (PROM)
Camshaft Sensor Camshaft Position Sensor (CMP Sensor)
Canister Purge (CP) Evaporative Emission Canister Purge (EVAP Canister
Purge)
Catalytic Converter (Cat. Conv.) 1. Oxidation Catalytic Converter (OC)
2. Three Way Catalytic Conveter (TWC)
3. Three Way and Oxidation Catalytic Converter
(TWC&OC)
4. Warmup Oxidation Catalytic Converter (WU-OC)
5. W arm u p T h re e W ay C a ta ly tic C o n v e rte r
(WU-TWO)
Check Engine Indicator Malfunction Indicator Lamp (MIL)
amTT -----
Code Diagnostic l rouble Cod© (L) IC )
1 A J. 11 1 *| 1 ■,■ / 1V
C om puter ControllGCl Coil Ignition (C3I) electronic ignition
Computer Command Control (CCC) Engine Control Module (ECM)
Controlled Canister Purge (CCP) Evaporative Emission Canister Purge (EVAP Canister
Purge)
Coolant Temperature Switch (CTS) Engine Coolant Temperature Switch (ECT Switch)
Coolant Temperature Sensor (CTS) Engine Coolant Temperature Sensor (ECT Sensor)
^ I" T~ • | //> .. [-** \ \
Cooling Fan Control c o o lin g ra n c o n tro l (oooung rU )
Detonation Sensor Knock Sensor (KS)
Diagnostic Circuit Check Onboard Diagnostic System Check (OBD System
Check)
Digital Fuel Injection (DFI) 1. Multiport Fuel Injection (MFI)
2. Sequential Multiport Fuel Injection (SFI)
Digital Electronic Fuel Injection (DEFI) 1. Multiport Fuel Injection (MFI)
Direct Ignition System (DIS) Electronic Ignition System (El System)
Distributor HEI Module Distributor Ignition Control Module (Dl Control Module)
Distributorless Ignition System (DIS) Electronic Ignition (El)
Dual Bed Monolith (DBM) 1. Oxidation Catalytic Converter (OC)
2. Three Way Catalytic Converter (TWC)
Electric Air Control (EAC) Secondary Air Injection Bypass Valve (AIR Bypass
Valve)
Electric Air Switching (EAS) Secondary Air Injection Switching Valve (AIR Switching
Valve)
Electronic Control Module (ECM) Engine Control Module (ECM)
Electronic Fuel Injection 1. Multiport Fuel Injection (MFI)
3. Throttle Body Fuel Injection (TBI)
Electronic Spark Timing (EST) Ignition Control (IC)
Electronic Spark Timing Circuit (EST Circuit) Ignition Control Circuit (IC Circuit)
Electronic Spark Timing System (EST System) Distributor Ignition System (Dl System)
J1930 CONVERSION CHART

From To
Electronic Spark Control Circuit (ESC Circuit) Knock Sensor Circuit (KS Circuit)
Electronic Spark Control System (ESC System) Knock Sensor System (KS System)
Electronic Vacuum Regulator Valve (EVRV) Exhaust Gas Recirculation Electronic Vacuum Regula
tor Solenoid Valve
Engine Calibration Unit (ECU) Programmable Read Only Memory (PROM)
Evaporative Emission Control System (EECS) Evaporative Emission Control System (EVAP Control
System)
Evaporative Emission Control System (EECS) Evaporative Emission System (EVAP System)
Exhaust Gas Recirculation/Thermostatic Vacuum Exhaust Gas Recirculation Thermal Vacuum Valve
Switch (EGR/TVS) (EGR TVV)
Fuel Cal-Pak Missing PROM Missing
Generator (Gen) Generator (GEN)
Governor Engine Speed Governor (RPM Governor)
High Energy Ignition (HEI) Distributor Ignition (Dl)
Lean Exhaust 1. Heated Oxygen Sensor Signal (H02S Signal)
2. Oxygen Sensor Signal (02S Signal)
Manifold Air Temperature Sensor (MAT Sensor) Intake Air Temperature Sensor (IAT Sensor)
Mem-Cal Error 1. EPROM Error
2. PROM Error
Memory and Calibration Unit (MEM-CAL) 1. Erasable Programmable Read Only Memory
(EPROM)
2. Programmable Read Only Memory (PROM)
Mixture Control (M/C) Mixture Control (MC)
Multi-Port Fuel Injection (MPFI) Multiport Fuel Injection (MFI)
Nitrogen Oxides (NOx) Nitrogen Oxides (NOx)
Oxygen (0„) Oxygen (02)
Oxygen Sensor (02) 1. Heated Oxygen Sensor (H02S)
2. Oxygen Sensor (02S)
Park/Neutral Switch (P/N Switch) Park/Neutral Position Switch (PNP Switch)
Port Fuel Injection (PFI) Multiport Fuel Injection (MFI)
Power Steering (P/S) Power Steering (PS)
Power Steering Switch Power Steering Pressure Switch (PSP Switch)
Pulse Air Injection System (PAIR) Pulsed Secondary Air Injection System (PAIR System)
Revolutions Per Minute (RPM) Engine Speed (RPM)
Rich Exhaust 1. Heated Oxygen Sensor Signal (H02S Signal)
2. Oxygen Sensor Signal (02S Signal)
“Scan” Data Scan Tool Data (ST Data)
Sequential Fuel Injection (SFI) Sequential Multiport Fuel Injection (SFI)
Sequential-port Fuel Injection (SFI) Sequential Multiport Fuel Injection (SFI)
Service Engine Soon Indicator (SES Indicator) Malfunction Indicator Lamp (MIL)
Thermal Vacuum Switch (TVS) Thermal Vacuum Valve (TVV)
Thermostatic Air Cleaner (TAC) Air Cleaner (ACL)
Throttle Body Injection (TBI) Throttle Body Fuel Injection (TBI)
Throttle Switch 1. Closed Throttle Position Switch (CTP Switch)
2. Wide Open Throttle Switch (WOT Switch)
Throttle Position Sensor (TPS) Throttle Position Sensor (TP Sensor)
Throttle Position Switch (TPS) 1. Closed Throttle Position Switch (CTP Switch)
2. Wide Open Throttle Switch (WOT Switch)
Tuned Port Injection (TPI) Multiport Fuel Injection (MFI)
Transmission/Transaxle Converter Clutch (TCC) Torque Converter Clutch (TCC)
Viscous Converter Clutch (VCC) Torque Converter Clutch (TCC)
T2934
Figure 15—J1930 Conversion Table
AIR CONDITIONING 1-1
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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HR100T/HR110MD AIR CONDITIONING COMPRESSOR 1D1 -1
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
1 — CLUTCH HUB KEY
2 — CLUTCH DRIVE
ASSEMBLY
3 — RETAINER RING,
ROTOR & BEARING
ASSEMBLY
4 — PULLEY ROTOR
5 — ROTOR BEARING
6 — COIL & HOUSING

ASSEMBLY
7 — RETAINER, SHAFT
SEAL
8 — SHAFT SEAL
9 — O-RING, 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
20 — WEEPAGE SEAL (FELT

WASHER)
COMPRESSOR - REAR HEAD

AS VIEWED IN DIRECTION
OF ARROW “A”
Fig. 1 Compressor Components — Disassembly

HR100T/HR110MD AIR CONDITIONING COMPRESSOR 1 P 1 -3
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.
1 -J-33013-B HUB AND 2 -CLUTCH PLATE AND

CLUTCH DRIVE HUB ASSEMBLY
PLATE ASSEMBLY
REMOVER
Fig. 4 Clutch Plate & Hub Asm. Removal
COMPRESSOR CLUTCH PLATE AND HUB

Fig. 2 Compressor, Poly-Groove Pulley Type with 6 Pole ASM
Clutch and Driver
Remove or Disconnect
1 -SUCTION PORT 1. If compressor is on the vehicle, loosen compressor

2 -SEALING mounting brackets, disconnect the compressor drive belt
WASHER and reposition the compressor for access, if necessary.
3 -DISCHARGE If compressor has been removed from the vehicle, attach
PORT
the compressor to Holding Fixture J 25008-A and clamp
4 -HIGH
PRESSURE the Holding Fixture in a vise (Fig. 5).
RELIEF
5 - J 25008-A
HOLDING
FIXTURE
6 -HIGH 1 -CLUTCH
PRESSURE PLATE AND
CUT-OFF HUB
SWITCH ASSEMBLY
Fig. 3 Compressor In Holding Fixture 2 -SEALING
WASHER
The Compressor Shaft Seal assembly, High Pressure 3 -SH AFT KEY
Cut-Off Switch and Pressure Relief Valve may also be serviced 4 - J 25008-A
W ITHOUT REMOVING THE COMPRESSOR from the HOLDING
vehicle but these operations are covered later in this section as FIXTURE
MAJOR REPAIR PROCEDURES because the refrigerant
5 - J 25008-A
system must be reclaimed, evacuated and recharged to HOLDING
complete service. FIXTURE
Illustrations used in describing these operations show the
compressor removed from the vehicle only to more clearly
illustrate the various operations. Fig. 5 Installing Shaft Key
1D 1-4 HR100T/HR110MD AIR CONDITIONING COMPRESSOR
Compressor mounting holes are metric. Use 6. If operation is performed with compressor on vehicle,
proper metric bolts with holding fixture connect drive belt, tighten mounting brackets and adjust
J 25008-A. belt tension.
Thread the Clutch Plate and Hub Assembly Remover

J33013-B, into the hub. Hold the body of the Remover 1 - J 6083
with a wrench and turn the center screw into the PLIERS
Remover body to remove the Clutch Plate and Hub 2 -CLUTCH
assembly (Fig. 4). ROTOR
Remove the shaft key. (Fig. 5.)
+ + 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.
The shaft key is curved slightly to provide an

interference fit in the shaft key groove of the hub.
Fig. 7 Removing Rotor & Bearing Asm. Retainer Ring
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 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.
C. Plug clutch coil connector onto Clutch Coil.

NOTICE: To avoid internal damage to the
compressor, do not drive or pound on the clutch hub or D. Position the Clutch Coil so the three (3) locating
shaft. tabs will align with the holes in the head and
continue to drive the Rotor and Bearing assembly
4. Install the Clutch Plate and Hub Installer J 9401-B as onto the front head.
illustrated in Figure 6.
E. Install the retainer ring (Fig. 7).
5. Hold the hex portion of the Installer Body J 9401-B with
F. Reassemble the Clutch Plate and Hub with the
a wrench and tighten the center screw to press the hub
shaft key onto the shaft with Installer J 9 4 0 1-B
onto the shaft until there is a 0.4-0.5m m (.0 1 5 -0 2 0 ") air
until 0.5-7.6mm (0.20-.030") air gap is obtained.
gap between the frictional surfaces of the Clutch Plate
and clutch rotor. Check for proper positioning of the G. Install shaft lock nut. Torque to 14 N«m
shaft key (even or slightly above the clutch hub). (lO lb.ft.).
HR100T/HR110MD AIR CONDITIONING COMPRESSOR 1P 1-5
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
Fig. 12 Bearing Removal

Fig. 10 Pulley Rotor & Bearing Puller Installation
J 29886
CLUTCH ROTOR AND/OR BEARING DRIVER
HANDLE
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
Fig. 14 Bearing Staking
Install or Connect
Place the Pulley Rotor on the J 21352-A Support Block

to fully support the rotor hub during bearing installation
(Fig. 13). Do not support the rotor by resting the pulley
rim on a flat surface during the bearing installation or the
rotor face will be bent.
Align the new bearing squarely with the hub bore and
using Puller and Bearing Installer J 9481-A with
Universal Handle J 29886, drive the bearing fully into
hub (Fig. 13). The Installer will apply force to the outer
race of the bearing if used as shown.
Place Bearing Staking Guide J 33019-1 and Bearing
Staking Pin J 33019-2 in the hub bore as shown in Figure
14. Shift the rotor and bearing assembly on the
J 21352-A Support Block to give full support of the hub
under the staking pin location. A heavy duty rubber band
may be used to hold the stake pin in the guide (Fig. 13),
COMPRESSOR CLUTCH COIL AND/OR
and the stake pin should be properly positioned in the
PULLEY RIM
guide after each impact on the pin. CLUTCH COIL AND PULLEY RIM INSTALLATION AND
Using care to prevent personal injury, strike the staking REMOVAL PROCEDURES USE REMOVAL OR
pin with a hammer until a metal stake, similar to the DISCONNECT PROCEDURE.
original, is formed down to, but not touching, the
bearing. Poly-Groove Drive
NOTICE: Noisy bearing operation and reduced 4> + Remove or Disconnect
bearing life may result if outer bearing race is deformed
while staking. The stake metal should not contact the 1. Remove the clutch plate and hub assembly as described
outer race of the bearing to prevent the possibility of previously.
distorting the outer race. Stake three (3) places 120° 2. Remove the pulley rotor and bearing assembly as
apart as shown in Figure 15. described previously. Mark the location of the clutch coil
With the compressor mounted to the J 25008-A Holding terminals on the compressor.
Fixture, position the Rotor and Bearing Assembly on the 3. Install Rotor and Bearing Puller Guide J 25031 to the
front head (Fig. 16). Using Rotor and Bearing Installer J front head and install Puller J 8433 with Poly-V-Belt
9481-A and Universal Handle J 29886 drive the rotor Puller Leg Set J 24092 and remove the clutch coil from
and bearing assembly onto the front head. With the the front head (Fig. 17). Clutch coil may also be removed
Installer assembled to the Handle as shown in Figure 16, by using rotor and bearing puller guide J 25031 with
force will be applied to the inner race of the bearing when puller tool J 25287 (Fig. 18).
HR100T/HR110MD AIR CONDITIONING COMPRESSOR 1P 1 -7
Poly-Groove Drive
Install or Connect
1. Place the clutch coil assembly on the neck of the front
head with clutch coil terminals in line with mark
described in Step 2 of the removal procedure.
2. Place the pulley rotor and bearing assembly on the neck
of the front head and seat the clutch coil and pulley rotor
in place using Rotor and Bearing Installer J 26271-A
(Fig. 8).
Before fully seating the assembly on the front head, be
sure the clutch coil terminals are in proper location in
relation to the compressor and that the three protrusions
on the rear of the clutch coil housing align with the
locater holes in the front head.
3. Install the pulley-rotor and bearing assembly retaining
ring and reassemble the clutch plate and hub assembly as
described in “Clutch Plate and Hub Assembly-Replace”.
4. Check to see that the clutch plate to clutch rotor air gap is
0.4-0.5m m (.015-.020").
1 - J 24092 PULLER LEGS

MAJOR REPAIR PROCEDURES
Service repair procedures to the Compressor Shaft
2 - J 8433 PULLER Seal, Pressure R elief Valve and Compressor Switches are
3 - J 25031 GUIDE considered “M AJOR” SINCE THE REFRIGERATION
MUST BE RECOVERED, EVACUATED AND
4 -CLUTCH COIL
RECHARGED to complete service.
Fig. 17 Removing Poly-Groove Clutch Coil When replacing the shaft seal assembly compressor
switches or pressure relief valve (Fig. 1), even if the
compressor remains on the vehicle during the operation, it will
be necessary to recover refrigerant. Other than clutch repair
procedures, the same holds true for any disassembly of the
compressor.
A clean workbench, preferably covered with a sheet of
clean paper, orderliness in the work area and a place for all parts
being removed and replaced is of great importance, as is the use
of the proper, clean service tools.
NOTICE: Any attempt to use make-shift or
inadequate equipment may result in damage and/or
improper compressor operation.
COMPRESSOR SHAFT SEAL

Shaft Seal Design
The shaft seal is a lip seal, one piece design.
Seal Leak Detection

A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface. Only change a
shaft seal when a leak is found by using an approved leak
Detector, J 39400 or equivalent.
On-Vehicle
1 - J 25287 CLUTCH COIL PULLER Remove or Disconnect
2 - J 25031 GUIDE 1. Recover Refrigerant using J 39500-GM.

3 - J 25008-A HOLDING FIXTURE 2. Loosen and reposition compressor in mounting brackets,
4 -CLUTCH COIL if necessary.
3. Remove Optional Dust Cover and Clutch Plate and Hub
Fig. 18 Removing Poly-Groove Clutch Coil
assembly from compressor as described in Minor
(Optional Method)
Repairs.
4. Remove the shaft seal seat retainer ring, using Snap Ring
Pliers J 5403.
5. Thoroughly clean inside of compressor neck area and
O-ring groove surrounding the shaft, the exposed portion
of the seal seat and the shaft itself. Any dirt or foreign
material getting into compressor may cause damage.
6. Remove Lip Seal:
Fully engage the knurled tangs of Seal
Remover-Installer J 23128-A into the recessed portion
of the Seal by turning the handle clockwise. Remove the
Seal from the compressor with a rotary-pulling motion.
Discard the Seal. The handle must be hand-tightened
securely. Do not use a wrench or plier (Fig. 19).
7. Remove and discard the seal seat O-ring from the
compressor, neck using O-Ring Remover J 9553-01.
8. Recheck the shaft and inside of the compressor neck and
O-ring groove for dirt or foreign material and be sure
these areas are perfectly clean before installing new
parts.
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
Fig. 19 Removing and Installing Seal and O-Ring

(One Piece Seal)
HR100T/HR110MD AIR CONDITIONING COMPRESSOR 1D 1-9
7. Remove any excess oil, resulting from installing the new
seal parts, from the shaft and inside the compressor neck.
1 -SN AP RING
PLIERS 8. Install the Clutch Plate and Hub assembly as described in
J 5403 minor repair procedures.
2 -S E A L SEAT 9. Reinstall compressor belt and tighten bracketry.
RETAINER
RING 10. Evacuate and Charge the Refrigerant System using
J 39500-GM.
11. Leak Test Refrigerant System using J 39400 Leak
Detector.
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
Insert the O-Ring Installer J 33011 completely down into

the compressor neck until the Installer “bottoms”. Lower
the moveable slide of the O-Ring Installer to release the
O-Ring into the seal seat O-ring lower groove. (The
compressor neck top groove is for the shaft seal retainer
ring.) Rotate the Installer to seat the O-ring and remove
the Installer.
Prepare Lip Seal: Fig. 21 Compressor Leak Testing Fixture
• Dip the new Lip Seal in clean 525 viscosity
Refrigerant Oil and assemble Lip Seal to Seal Off-Vehicle
Installer, J 23128-A , (Fig. 19). The printed/
stamped steel case side of Lip Seal must be «■ Install or Connect
engaged with knurled tangs of installer so that
flared-out side of Lip Seal is facing and installed 1. Follow applicable on-vehicle procedures.
towards the compressor. 2. To leak test, install compressor leak test fixture J 9625-A
(Fig. 21) on rear head of compressor and connect gage
Install Lip Seal:
charging lines and J 39500-GM Refrigerant Recovery &
• Place Seal Protector J 34614 over end of
Recycling System. Pressurize suction and high-side of
compressor shaft and slide new seal onto the shaft
compressor with R 134a Refrigerant. Temporarily install
with a rotary motion until it stops (Fig 19). Take
(M9 x 1.25 thread on shaft) nut and, with the compressor
care not to dislodge the O-Ring. Disengage
in horizontal position, rotate the compressor shaft in
installer from seal and remove seal protector from
normal direction of rotation several turns by hand. Leak
compressor shaft.
test the seal area and correct any leak found. Recover the
NOTICE: Handling and care of seal protector is refrigerant. Remove shaft nut.
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during installation.
COMPRESSOR PRESSURE RELIEF VALVE
Install the new seal seat retainer ring with its flat side
against the Seal Seat, using Snap-Ring Pliers J 5403 (Fig Remove or Disconnect
20). Use the sleeve from O-Ring Installer J 33011 to press
in on the seal seat retainer ring so that it snaps into its 1. Recover the refrigerant using J 39500-GM.
groove.
2. Remove old pressure relief valve (Fig. 19).
To leak test, install compressor leak test fixture
J 39893 on rear head of compressor and connect gage Install or Connect
charging lines and J 39500-GM Refrigerant Recovery
System. Pressurize suction and high-side of compressor 1. Clean valve seat area on rear head.
with R-134a Refrigerant. Temporarily install (M9 x 1.25 2. Lubricate O-ring of new pressure relief valve and O-ring
thread on shaft) nut and, with the compressor in assembly with new 525 viscosity refrigerant oil. Install
horizontal position, rotate the compressor shaft in new valve and torque in place, 9.0 N*m (6.1 lbs.-ft.)
test the seal area and correct any leak found. Recover the 3. Evacuate and recharge the system using J 39500-GM.
refrigerant. Remove shaft nut. 4. Leak test system using J 39400.
0
COMPRESSOR CONTROL SWITCHES Install or Connect
1. Check switch cavity and O-ring groove in the rear head
l. Recover the refrigerant using J 39500-GM . for dirt or foreign material and clean as necessary. Install
2. Disconnect the electrical connector from the switch in new O-ring coated with clean 525 viscosity refrigerant
the rear head of the compressor. oil into groove in switch cavity.
3. Remove the switch retaining ring (Fig. 22) using 2. Lubricate the switch housing with clean 525 viscosity
J 5403 internal snap ring pliers. refrigerant oil and carefully insert switch into switch
4. Remove switch from compressor by pulling on terminal cavity until switch bottoms in cavity.
housing. 3. Using J 5403 snap ring pliers, install switch retaining
5. Remove old O-ring seal from switch cavity using ring with high point of curved sides adjacent to the
J 9553-01 O-ring removal tool or equivalent. switch housing. Be sure retaining ring is properly seated
If switch will be reinstalled in compressor, a new O-ring in the switch cavity retainer ring groove.
seal must be used and preferably a new retainer ring
should also he used. A new switch kit has the O-ring and
retainer ring included.
1 -H IG H
PRESSURE
CUT-OFF
SWITCH
2 - “O” RING
3 -SWITCH
RETAINNING
RING
Fig. 22 High Pressure Cut-Off Switch and Retainer

HR100T/HR110MD AIR CONDITIONING COMPRESSOR 1D1 -11
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
Fig. 23 HR100T/HR110MD Compressor — Special Tools

1D1-12 HR100T/HR110MD AIR CONDITIONING COMPRESSOR
BLANK
HP6/HR6-HE AIR CONDITIONING COMPRESSOR 1P2-1
SECTION 1D2
HD6/HR6-HE
AIR CONDITIONING COMPRESSOR
SERVICE OR UNIT REPAIR R-134a
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.
When servicing the compressor, keep dirt or foreign

material from getting on or into the compressor parts and
system. Clean tools and a clean work area are important for
proper service. The compressor connections and the outside of
the compressor should be cleaned before any “on vehicle”
Q ] W IT H O U T T O R Q U E repairs, or before removal of the compressor. The parts must be
C U S H IO N
kept clean at all times and any parts to be reassembled should
0 TORQUE be cleaned with trichloroethane, naphtha, Stoddard solvent,
C U S H IO N
kerosene or equivalent and dried with dry air. When necessary
to use a cloth on any part, it should be of a non-lint producing
Fig. 1 Clutch Driver Designs type.
Although this compressor is the same for all vehicle
applications, there are differences in installations, mounting The operations described below are based on bench
brackets, pulleys, torque cushions and switches, none of which overhaul with the compressor removed from the vehicle,
will affect the following overhaul procedures. except as noted. They have been prepared in order of
There are two clutch driver designs for these accessibility of the components. When a compressor is
compressors. The clutch driver without a torque cushion and removed from the vehicle for servicing, the amount of PAG
the clutch driver having a thin torque cushion (Fig. 1). lubricant remaining in the compressor should be drained,
1D 2-2 HD6/HR6-HE AIR CONDITIONING COMPRESSOR
1 — CLUTCH DRIVER
2 — ROTOR BEARING
RETAINER
3 — PULLEY BEARING
4 — PULLEY
5 — CLUTCH COIL
ASSEMBLY
6 — SHAFT SEAL PARTS
7 — PUMP ASSEMBLY
8 — SWITCH O-RING
SWITCH
RELIEF VALVE
11 — RETAINER RING SWITCH
12 — SUCTION/DISCHARGE
PORT SEALING
WASHERS
13 — SPECIAL 134a SUCTION

PORT
14 — SPECIAL 134a
DISCHARGE PORT
Compressor — Rear Head

As Viewed in Direction of Arrow “A”
Fig. 2 Compressor Components — Disassembly

HD6/HR6-HE AIR CONDITIONING COMPRESSOR 1D 2-3
measured and recorded. This PAG lubricant should then be METRIC THREAD SIZE INFORMATION
discarded and an equal amount of new PAG lubricant added to
1. Compressor to mounting bracket bolts.
the compressor.
Front M10 x 1.5 - 6H
The service compressor is shipped with 240 ml (8 oz.) of Rear M 8 x l .2 5 - 6 H
PAG lubricant. This lubricant should be drained and retained
2. Suction-discharge port screw.
for use as replacement lubricant when service procedures
M lO x 1.5 - 6 H
require addition of new lubricant to compressor. NOTE:
Replace only with GM approved PAG oil P/N 12345923. 3. Compressor shaft.
M9 x 1.25 - 6 H
Most minor repair procedures may be done on the
vehicle without discharging the system. M ajor repair 4. Internal hub-clutch drive assembly.
procedures require that the system be discharged of refrigerant. M 22x 1 .5 - 6 H
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.
COMPRESSOR CLUTCH PLATE AND HUB

ASSEMBLY
«■ Remove or Disconnect
m J 33013-B HUB AND Q ] J 33026 HOLDING
1. Clamp the holding fixture J 33026 in a vise and attach CLUTCH DRIVE PLATE FIXTURE
compressor to holding fixture with thumb screws
ASM. REMOVER CLUTCH pLAT£
J 33026-1 (Fig. 3).
[ T | J 33026 1 THUMB AND HUB ASM.
With center screw forcing tip in place to thrust against
SCREW
the end of the shaft, thread the Clutch Plate and Hub
G 6 0 0 7 0 -1 D 2 -C -R 1
Assembly Installer-Remover J 33013-B into the hub.
Hold the body of the remover with a wrench and turn the Fig. 3 Clutch Plate and Hub Assembly Removal
NOTICE: 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 wedge and will break the clutch hub.
□ CLUTCH PLATE AND HUB ASSY
m CLUTCH PULLEY ROTOR
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.
4. Remove the forcing tip on J 33013-B clutch plate and G 6 0 0 9 0 - 1 D 2 - C —R1

hub assembly installer-rem over center screw and
Fig. 5 Installing Clutch Plate & Hub Assembly
reverse the body direction on the center screw, as shown
in Figure 5. 7. Remove installer J 33013-B, check for proper
positioning of the shaft key (even or slightly above the
5. Install the clutch plate and hub installer-remover
clutch hub).
J 33013-B with bearing as shown in Figure 8.
8. Spin the pulley rotor by hand to see that the rotor is not
The body of the J 33013-B installer-rem over should be rubbing the clutch drive plate.
backed off sufficiently to allow the center screw to be
threaded onto the end of the compressor shaft.
COMPRESSOR CLUTCH ROTOR AND/OR
6. Hold the center screw with a wrench. Tighten the hex
portion of the installer-rem over J 33013-B body to press
BEARING
the hub onto the shaft. Tighten the body several turns,
remove the installer and check to see that the shaft Remove or Disconnect
key is still in place in the keyway before
installing the clutch plate and hub assembly to 1. Remove the clutch plate and hub assembly as described
its final position. The air gap between frictional previously.
surfaces of the clutch plate and clutch rotor should be 2. Remove rotor and bearing assembly retaining ring, using
0.50-0.76m m (.020-.030"). snap ring pliers J 6083 (Fig. 6).
J 33020 PULLEY ROTOR

AND BEARING PULLER
G 6 0 1 2 0 -1 D 2 -E K -R 1
Fig. 8 Removing Pulley Rotor and Bearing Assembly
(T) J 6083
PLIERS
| T | PULLEY
ROTOR
[ T | RETAINING
RING
Fig. 6 Installing-Removing Pulley Rotor & Bearing Assembly

Retaining Ring
r n J 33020 (LESS m PULLEY ROTOR

FORCING SCREW) -FACE DOWN"
INVERTED AND
USED TO SUPPORT HI J 9398-A BEARING
REMOVER
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
Remove the forcing screw from J 33020 puller and, with

3. Install pulley rotor and bearing puller guide J 33023-A the puller tangs still engaged in the rotor slots, invert the
to the front head (Fig. 7) and install J 33020 pulley rotor assembly onto a solid flat surface or blocks as shown in
and bearing puller down into the inner circle of slots in Figure 9.
the rotor. Turn the J 33020 puller clockwise in the slots in
6. Drive the bearing out of the rotor hub with rotor bearing
the rotor (Fig. 8).
remover J 9398-A and J 29886 universal handle (Fig. 9).
4. Hold the J 33020 puller in place and tighten the puller
NOTICE: It is not necessary to remove the staking in
screw against the puller guide to remove the pulley rotor
front of the bearing to remove the bearing, however, it
and bearing assembly.
will be necessary to file away the old stake metal for
5. To prevent damage to the pulley rotor during bearing proper clearance for the new bearing to be installed into
removal the rotor hub must be properly supported. the rotor bore or the b e nr nav be •' n r -■!
1D 2-6 HP6/HR6-HE AIR CONDITIONING COMPRESSOR
h i J 33019-1 BEARING STAKING GUIDE

RUBBER BAND
[ T | J 3 3 0 19 -2 BEARING STAKING PIN
_______________________________________________ G 6 0 1 5 0 - 1 D 2 - E K - R 1
Fig. 11 Staking Bearing In Rotor Hub Bore
OH J 21352-A [ 4 ] J 9481-A BEARING

SUPPORT BLOCK INSTALLER
_________________________________________________________ G 6 0 1 4 0 - 1 D 2 - C - R 1 __________
Fig. 10 Installing Pulley Rotor Bearing
[» » | Install or Connect
1. Place the pulley rotor on the J 21352-A support block to

fully support the rotor hub during bearing installation
(Fig. 10).
NOTICE: DO NOT support the rotor by resting the
pulley rim on a flat surface during the bearing 5. With the compressor mounted to the J 33026 holding
installation or the rotor face will be bent. fixture, position the rotor and bearing assembly on the
front head (Fig. 13).
2. Align the new bearing squarely with the hub bore and 6. Position the J 33017 pulley, rotor and bearing installer
using puller and bearing installer J 9481-A with and J 33023-A puller pilot directly over the inner race of
universal handle J 29886, drive the bearing fully into the the bearing (Fig. 13).
hub (Fig. 10). The installer will apply force to the outer
race of the bearing, if used as shown. 7. Position puller crossbar J 8433-1 on the puller pilot
J 33023-A and assemble the two J 33026-2 through bolts
3. Place bearing staking guide J 33019-1 and bearing and washers through the puller bar slots and thread them
staking pin J 33019-2 in the hub bore as shown in into the J 33026 holding fixture (Fig. 13). The thread of
Figure 11. Shift the rotor and bearing assembly on the the through bolts should engage the full thickness of the
J 21352-A support block to give full support of the hub holding fixture.
under the staking pin location. A heavy-duty rubber
band may be used to hold the stake pin in the guide (Fig. 8. Tighten the center screw in the J 8433-1 puller crossbar
11), and the stake pin should be properly positioned in to force the pulley rotor and bearing assembly onto the
the guide after each impact on the pin. compressor front head (Fig. 13). Should the
J 33017 pulley rotor and bearing installer slip off direct
4. Using care to prevent personal injury, strike the staking
in-line contact with the inner race of the bearing, loosen
pin with a hammer until a metal stake, similar to the
the J 8433-1 center forcing screw and realign the
original, is formed down to but not touching the
installer and pilot so that the J 33017 installer will
bearing. properly clear the front head.
Noisy bearing operation and reduced bearing life may
9. Install rotor and bearing assembly retainer ring, using
result if outer bearing race is deformed while staking,
snap ring pliers J 6083 (Fig. 6).
The stake metal should not contact the outer race of the
bearing. Stake three places 120 degrees apart as shown in 10. Reinstall clutch plate and hub assembly as described
!%»!*** 12. previously.
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
COMPRESSOR CLUTCH COIL

1. Perform Steps 1 through 4 of “Clutch Rotor and/or

Bearings” removal procedure. Mark clutch coil
terminal location on compressor front head.
2. Install J 33023-A puller pilot on front head of
compressor (Fig. 14). Also install J 8433-1 puller
crossbar with J 33025 puller legs as shown in Figure 14.
3. Tighten J 8433-3 forcing screw against the puller pilot to
remove the clutch coil.
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 countersunk
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).
G 6 0 1 8 0 - 1 D 2 - C —R1 4. Turn the center forcing screw of the J 8433-1 puller

Fig. 14 Clutch Coil Assembly Removal crossbar to force the clutch coil onto the front head. Be
sure clutch coil and J 33024 installer stay “in-line”
during installation.
1 - FRONT HEAD SURFACE 3 - CLUTCH

1—CLUTCH COIL 3-STAKE IN FRONT
HEAD (3 PLACES)
2 - STAKE FRONT HEAD 0.28-0.35MM RS!V„..
2 -D R IF T PUNCH DEEP (0.10-015") H0USING
5 2 0 0 2 0 - 1D2 520021-1 D 2
Fig. 16 Staking Clutch Coil to Front Head Fig. 17 Details of Stakes in Front Head for Clutch Coil
5. When coil is fully seated on the front head, use a 1/8"

diameter drift punch and stake the front head at three
places 120 degrees apart (Fig. 16), to ensure clutch coil
remains in position.
• Stake size should be only one-half the area of the

punch tip and be only approximately
0.28-0.35m m (.010-.015") deep (Fig. 17).
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
Fig. 18 Compressor Shaft Seal
MAJOR COMPRESSOR REPAIR 1 I SUCTION PORT r~4~] CONTROL

PROCEDURES 2 | DISCHARGE PORT
___ SWITCHES
[~~5~1 PRESSURE
T | MOUNTING BOSS (3) RELIEF VALVE
When replacing the shaft seal assembly (Fig. 18),
pressure relief valve or control switches (Fig. 19), it will be
necessary to recover the refrigerant. Other than clutch repair
procedures, the same holds true for any disassembly of the
compressor.
A clean workbench covered with a sheet of clean paper,

and a place (clean trays, etc.) for all parts being removed and
replaced is important, as is the use of proper clean service tools.
NOTICE: Any attempt to use makeshift or

inadequate service tools or equipment may result in
damage and/or improper compressor operation.
5 2 0 0 2 0 -1 D 2 - R 1
All parts required for servicing the internal compressor
are protected by a preservative process and packaged in a Fig. 19 Compressor— Rear Head
manner which will eliminate the necessity of cleaning,
washing or flushing o f the parts. The parts can be used in the COMPRESSOR SHAFT SEAL
internal assembly just as they are removed from the service REPLACEMENT
package. Seals and protective packaging should be left Seal Leak Detection
intact until just prior to installation.
A shaft seal should not be changed because of small
If the compressor rear head, front head or cylinder and amounts of oil found on an adjacent surface but only after
shaft assembly is to be serviced or replaced, the oil in the actual refrigerant leakage is found using an approved leak
compressor must be drained, measured, recorded and replaced. detector, J 39400 or equivalent.
1. Recover the refrigerant using J 39500-GM.

2. Loosen and reposition compressor in mounting brackets,
if necessary.
3. Remove clutch plate and hub assembly from compressor
as described in minor repairs.
4. Remove the shaft seal retainer ring, using snap ring
pliers J 5403 (Fig. 21).
5. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the seal, the
retainer ring groove and the shaft itself. Any dirt or
foreign material getting into compressor may cause
damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J 23128-A into the recessed portion of the Seal
by turning the handle clockwise. Remove the Seal from
the compressor with a rotary-pulling motion (Fig. 22).
Discard the seal. The handle must be hand- tightened
securely. Do not use a wrench or pliers.
Remove and discard the seal seat O-ring from the
compressor neck using O-ring remover J 9553-01,
Figure 20.
Recheck the shaft and inside of the compressor neck for
dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.
• Thoroughly clean O-ring seal groove in front head.

NOTICE: Seals should not be re-used. Always use a
new specification service seal on rebuild (Fig. 18). Be
sure that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat and seal
are free o f lint and dirt that could damage the seal surface
or prevent sealing.
+ «■ Install or Connect
Dip the new seal seat O-ring in clean 525 viscosity

refrigerant oil and assemble onto O-ring installer
J 33011, Figure 20.
2. Insert the O-ring installer J 33011 into the compressor
neck until the installer “bottoms”. Lower the moveable
slide of the O-ring installer to release the O-ring into the
seal O-ring lower groove. (The compressor neck top
groove is for the shaft seal retainer ring.) Rotate the
installer to seat the O-ring and remove the installer.
3. Dip the new seal in clean 525 viscosity refrigerant oil and
assemble seal to Seal Installer J 23128-A , by turning
[7] SEAL [ | ] J 9553-01 [ | ] J 33011 handle clockwise. The stamped steel case side of the
[T] J 23128-A 0 O-RING [ | ] J 34614 lip seal must be engaged with knurled tangs of installer
so that flared-out side of lip seal is facing and
installed towards the compressor. Install seal protector
Fig. 20 Removing and Installing Shaft Seal and O-Ring J 34614, in the seal lip and place over the compressor
shaft, Figure 22, and push the seal in place with a
rotary motion or place the seal protector J 34014 over
end of compressor shaft. Figure 22, and slide the new
1D2-10 HD6/HR6-HE AIR CONDITIONING COMPRESSOR
4. Install the new seal retainer ring with its flat side against
the Seal, using Snap-Ring Pliers J 5403. See Figure 21.
Use the sleeve from O-ring installer J 33011 to press in on
the seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J 39893 on rear head of compressor and connect gage
charging lines and J 39500-GM Refrigerant Recovery
System. Pressurize suction and high-side of compressor
with R-134a Refrigerant. Temporarily install (M9 x 1.25
thread on shaft) nut and, with the compressor in
horizontal position, rotate the compressor shaft in
test the seal area and correct and leak found. Recover the
refrigerant. Remove shaft nut.
6. Remove any excess oil resulting from installing the new
seal parts from the shaft and inside the compressor neck.
7. Install the clutch plate and hub assembly as described in
minor repair procedures.
8. Reinstall compressor belt and tighten bracket.
9. Evacuate and charge the refrigerant system.
COMPRESSOR PRESSURE RELIEF VALVE

E3 Remove or Disconnect
1. Recover the refrigerant using J 39500-GM.
Fig. 21 Removing or Installing Shaft Seal
Retaining Ring 2. Remove old pressure relief valve (Fig. 19).
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.
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

HD6/HR6-HE AIR CONDITIONING COMPRESSOR 1D2-11
CONTROL SWITCHES 6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make
Figure 20 certain the leak has been corrected.
7. Recover the refrigerant.
8. Disconnect both hoses from the test plate J 39893.
1. Recover the refrigerant. 9. Add 90 ml (3 oz.) new PAG lubricant to the compressor
2. Disconnect the electrical connector from the switch in assembly. Rotate the complete compressor assembly
the rear head of compressor. (not the crankshaft or drive plate hub) slowly several
turns to distribute oil to all cylinder and piston areas.
3. Remove the switch retaining ring using J 5403 internal
snap ring pliers. 10. Install a M9 x 1.25 threaded nut on the compressor
crankshaft if the drive plate and clutch assembly are not
4. Remove the switch from the compressor. installed.
5. Remove old O-ring seal from the switch cavity using
11. Using a box-end wrench or socket and handle, rotate the
J 9553-01 O-ring removal tool.
compressor crankshaft or clutch drive plate on the
If existing control switch is reinstalled in the compressor, crankshaft several turns to insure piston assembly to
a new O-ring seal must be used and preferably a new retainer cylinder wall lubrication.
ring should also be used. A new switch kit has the O-ring and
retainer ring included. 12. Using J 39500-GM Refrigerant Recovery System,
connect J 9893 the charging station high-pressure line to
E3 Install or Connect 13.
the test plate high-side connector.
Using J 39500-GM Refrigerant Recovery System,
1. Check switch cavity and O-ring groove in the rear head connect the charging station low-pressure line to the low
for dirt or foreign material and clean as necessary. Install pressure port of the test plate J 39893. Oil will drain out
a new O-ring coated with clean refrigerant oil into of the compressor suction port if the compressor is
groove in switch cavity. positioned with the suction port downward.
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.
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,
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
8 — J 9553-01 “0 ” RING REMOVER 1 9 — J 33023 PULLER PILOT
9 — J 39893 PRESSURE TESTING CONNECTOR 20 — J 33024 CLUTCH COIL INSTALLER ADAPTER
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
12 — J 33011 “O” RING INSTALLER 24 — J 39037 HIGH-SIDE CHARGE VALVE SOCKET
Fig. 23 Compressor Overhaul — Special Tools

V5 AIR CONDITIONING COMPRESSOR 1D3-1
SECTION 1D3
V5 AIR CONDITIONING
COMPRESSOR SERVICE OR
UNIT REPAIR R-134a
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
1 — DUST COVER &

SCREWS (SPECIAL
APPLICATIONS)
2 — SHAFT NUT
3 — CLUTCH HUB KEY
4 — CLUTCH DRIVER
5 — DUST SEAL (SPECIAL

APPLICATIONS)
RETAINER
8 — WEEPAGE SEAL - FELT

WASHER (SPECIAL
APPLICATIONS)
9 — PULLEY ROTOR
10 — CLUTCH COIL ASM.
11 — SHAFT SEAL PARTS
12 — SERVICE
COMPRESSOR
WITHOUT CLUTCH
13 — COMPRESSOR
CONTROL VALVE ASM.
14 — RETAINER RING
CONTROL VALVE
RELIEF VALVE
1 6 — RETAINER RING
SWITCH
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. 3 Compressor Components - Disassembled View

1 - J 34992 COMPRESSOR HOLDING FIXTURE
2 - CLUTCH PLATE AND HUB ASM.
3 - J 33022NUT SOCKET 1 - CLUTCH PLATE AND HUB

4 - J 33027—A CLUTCH HUB HOLDING TOOL 2 - SHAFT KEY
3 - SHAFT KEYWAY
5 - J 34992 THUMB SCREW
4 - CLUTCH PULLEY ROTOR
Fig. 4 Removing Shaft Nut Fig. 6 Shaft Key, Clutch Plate/Hub Installation
1 - CLUTCH PLATE AND HUB ASSEMBLY

1 - CLUTCH PLATE AND HUB ASSEMBLY
2 - J 3 3 0 1 3 -B HUB AND CLUTCH DRIVE
PLATE ASSEMBLY REMOVER 2 - J 3 3 0 1 3 -B DRIVE PLATE INSTALLER
3 - J 3 49 9 2 -1 THUMB SCREW 3 - DRIVE PLATE INSTALLER BEARING
4 - J 34992 HOLDING FIXTURE 4 - AIR GAP (.0 1 5 -.0 2 0 ") 0.40-0.50m m
Fig. 5 Clutch Plate and Hub Assembly Removal Fig. 7 Installing Clutch Plate & Hub Assembly
J 33020 PULLEY ROTOR

AND BEARING PULLER
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.
1 - J 33020 PULLER ENGAGES IN INNER COMPRESSOR CLUTCH ROTOR AND/OR

CIRCLE OF SLOTS IN ROTOR BEARING
2 - J 33023—A PULLEY ROTOR AND Remove or Disconnect
BEARING PULLER GUIDE
1. Remove the clutch plate and hub assembly as described
previously.
Fig. 9 Installing Pulley Rotor/Bearing Puller Guide 2. Remove rotor and bearing assembly retaining ring, using
1 - J 33020 (LESS 2 - PULLEY ROTOR

FORCING SCREW) “ FACE DOWN”
INVERTED AND USED
TO SUPPORT HUB OF 3 - J 8398—A BEARING 1 - J 8092 DRIVER 3 - PULLEY ROTOR
ROTOR FOR BEARING REMOVER HANDLE
REMOVAL, PULLER 4 - J 9481 - A BEARING
TANGS ENGAGED IN 4 - J 8092 DRIVER 2 - J 21352 SUPPORT INSTALLER
ROTOR SLOTS HANDLE BLOCK
Fig. 11 Pulley Rotor Bearing Removal Fig. 12 Installing Pulley Rotor Bearing
NOTICE: Do Not support the rotor by resting the

3. Install pulley rotor and bearing puller guide J 33023-A pulley rim on a flat surface during the bearing
to the front head (Fig. 9) and install J 33020 pulley rotor installation or the rotor face will be bent.
and bearing puller down into the inner circle of slots in
the rotor. Turn the J 33020 puller clockwise in the slots to 2. Align the new bearing squarely with the hub bore and
engage the puller tangs with the segments between the using puller and bearing installer J 9481-A with
slots in the rotor (Fig. 10). universal handle J 29886, drive the bearing fully into the
hub (Fig. 12). The installer will apply force to the outer
4. Hold the J 33020 puller in place and tighten the puller race of the bearing if used as shown.
screw against the puller guide to remove the pulley rotor
and bearing assembly. 3. Place bearing staking guide J 33019-1 and bearing
staking pin J 33019 in the hub bore as shown in Figure 13.
5. To prevent damage to the pulley rotor during bearing Shift the rotor and bearing assembly on the
removal the rotor hub must be properly supported. J 21352-A support block to give full support of the hub
Remove the forcing screw from J 33020 puller and, with under the staking pin location. A heavy-duty rubber band
the puller tangs still engaged in the rotor slots, invert the may be used to hold the stake pin in the guide (Fig. 13),
assembly onto a solid flat surface or blocks as shown in and the stake pin should be properly positioned in the
Figure 11. guide after each impact on the pin.
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).
1 - J 33019
BEARING
STAKING
GUIDE
2 - RUBBER
BAND
3 - J 33019
BEARING
STAKING
PIN
Fig. 13 Staking Bearing In Rotor Hub Bore
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
Fig. 16 Clutch Coil Assembly Removal

Fig. 14 Bearing Staked In Place
7. Position puller crossbar J 8433-1 on the puller pilot
J 33023-A and assemble the two J 34992-2 through bolts
and washers through the puller bar slots and thread them
into the J 34992 holding fixture (Fig. 15). The thread of
the through bolts should engage the full thickness of the
holding fixture.
8. Tighten the center screw in the J 8433-1 puller crossbar
to force the pulley rotor and bearing assembly onto the
compressor front head (Fig. 15). Should the J 33017
pulley rotor and bearing installer slip off direct in-line
contact with the inner face of the bearing, loosen the
J 8433-3 center forcing screw and realign the installer
and pilot so that the J 33017 installer will properly clear
the front head.
9. Install rotor and bearing assembly retainer ring, using
10. Reinstall clutch plate and hub assembly as described
previously.
COMPRESSOR CLUTCH COIL

1 - PULLEY ROTOR
2 - J 33017 PULLEY ROTOR
3 - J 8433-1 PULLER BAR l. Perform Steps 1 through 4 of “Clutch Rotor and/or
4 - J 8 4 3 3 -3 FORCING SCREW Bearings” removal procedure. Mark clutch coil terminal
location on compressor front head.
5 - J 330 23 -A PULLER PILOT
6 - J 34992 COMPRESSOR HOLDING FIXTURE 2. Install J 33023-A puller pilot on front head of
compressor (Fig. 16). Also install J 8433-1 puller
crossbar with J 33025 puller legs as shown in Figure 16.
Fig. 15 Installing Pulley Rotor and Bearing Assembly 3. Tighten J 8433-3 forcing screw against the puller pilot to
remove the clutch coil.
MAJOR COMPRESSOR REPAIR
PROCEDURES
When replacing the shaft seal assembly (Fig. 20),
pressure relief valve or rear head mounted pressure switches
(Fig. 2), even if the compressor remains on the vehicle during
the operation, it will be necessary to discharge the system of
refrigerant.
Other than clutch repair procedures, the same holds true
for any disassembly of the compressor.
A clean workbench covered with a sheet of clean paper,

and a place (clean trays, etc.) for all parts being removed and
replaced is important, as is the use of the proper, clean service
tools.
NOTICE: Any attempt to use makeshift or
inadequate service tools or equipment may result in
damage and/or improper compressor operation.
All parts required for servicing the internal compressor

are protected by a preservative process and packaged in a
1 - J 8 4 3 3 -3 SCREW manner which will eliminate the necessity of cleaning,
washing or flushing of the parts. The parts can be used in the
2 - J 8433 PULLER CROSS BAR
internal assembly just as they are removed from the service
3 - J 33024 CLUTCH COIL INSTALLER package. Seals and protective packaging should be left
4 - CLUTCH COIL ASSEMBLY intact until just prior to installation.
If the compressor rear head, front head or cylinder and

shaft assembly is to be serviced or replaced, the oil in the
Fig. 17 Installing Clutch Coil Assembly
compressor must be drained, measured, recorded and replaced.
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).
4. Turn the center forcing screw of the J 8433-1 puller

crossbar to force the clutch coil onto the front head. Be
sure clutch coil and J 33024 installer stay “in-line”
during installation.
5. When coil is fully seated on the front head, use a 1/8"

diameter drift punch and stake the front head at three (3)
places 120° apart (Fig. 18), to ensure clutch coil
1 - CLUTCH COIL
remaining in position.
2 - DRIFT PUNCH
• Stake size should be only one half the area of the 3 - STAKE IN FRONT
punch tip and only approximately 0.28-0.35mm HEAD (3 PLACES)
(.010—.015") deep (Fig. 19).
6. Install rotor and bearing assembly and the clutch plate

and hub assembly according as described previously. Fig. 18 Staking Clutch Coil To Front Head
7. Install shaft nut.

COMPRESSOR SHAFT SEAL 6. Fully engage the knurled tangs of seal remover-installer
REPLACEMENT J 23128-A into the recessed portion of the seal by turning
the handle clockwise. Remove the seal from the
Seal Leak Detection compressor with a rotary-pulling motion (Fig. 24).
Discard the seal. The handle should be hand-tightened
A shaft seal should not be changed because of small securely. Do not use a wrench or pliers.
amounts of oil found on an adjacent surface. The seal is
7. Remove and discard the seal O-ring from the compressor
designed to leak some oil for lubrication puiposes. A shaft seal
neck using O-ring remover J 9553-01 (Fig. 22).
should be changed only when a large amount of sprayed oil is
found, and only after actual refrigerant leakage is found by Recheck the shaft and inside of the compressor neck for
using an approved leak detector, J 39400 or equivalent. dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.
Clean
Thoroughly clean seal O-ring groove in front head.

NOTICE: Seals should not be re-used. Always use a
new specification service seal kit (Fig. 20). Be sure that
the seal to be installed is not scratched or damaged in any
way. Make sure that the seal is free of lint and dirt that
could damage the seal surface or prevent sealing.
Dip the new seal O-ring in clean 525 viscosity refrigerant

oil and assemble onto O-ring installer J 33011. (Fig. 23)
1 - FRONT HEAD SURFACE 3 - CLUTCH “New”.
2 - STAKE FRONT HEAD COIL
0.28-0.35MM DEEP (.010-.015") HOUSING Insert the O-ring installer J 33011 into the compressor
neck until the installer “bottoms.” Lower the moveable
slide of the O-ring installer to release the O-ring into the
Fig. 19 Details of Stakes In Front Head for Clutch Coil seal O-ring lower groove. (The compressor neck top
groove is for the shaft seal retainer ring.) Rotate the
installer to seat the O-ring and remove the installer.
Dip the new seal in clean 525 viscosity refrigerant oil and
assemble seal to Seal Installer J 23128-A , by turning
handle clockwise. The stamped steel case side of the
lip seal must be engaged with knurled tangs of installer
so that flared-out side of lip seal is facing and installed
towards the compressor. Install shaft seal protector
J 34614 on the lip seal, Figure 25. Place the seal protector
J 34614 over end of compressor shaft, and slide the new
seal onto the shaft with a rotary motion until it stops.
Take care not to dislodge the O-ring. Be sure the seal
1 - STEEL SHELL makes good contact with the O-ring. Disengage the
2 - LIP SEAL installer from the seal and remove the installer
J 23128-A and the shaft seal protector J 34614.
Fig. 20 Compressor Shaft Seal NOTICE: Handling and care of seal protector is
14* +| Remove or Disconnect flared, the new seal may be damaged during installation.
Install the new seal retainer ring with its flat side against
1. Recover refrigerant using J 39500-GM. the seal, using snap-ring pliers J 5403 (Fig. 21). Use the
sleeve from O-ring installer J 33011 to press in on the
2. Loosen and reposition compressor in mounting brackets. seal retainer ring so that it snaps into its groove.
3. Remove clutch plate and hub assembly from compressor To leak test, install compressor leak test fixture
as described in minor repairs. J 39893 on rear head of compressor and connect gage
charging lines using J 39500-GM Refrigerant Recovery
4. Remove the shaft seal retainer ring, using snap ring
System. Pressurize suction and high-side of compressor
pliers J 5403 (Fig. 21).
with R134a Refrigerant. Temporarily install the shaft nut
5. Thoroughly clean inside o f compressor neck area and, with the compressor in horizontal position, rotate
surrounding the shaft, the exposed portion o f the seal, the the compressor shaft in normal direction of rotation
shaft itself and O-ring groove. Any dirt or foreign several turns by hand. Leak test the seal area and correct
material getting into compressor may cause damage. any leak found. Recover refrigerant. Remove shaft nut.
Install or Connect
l. Clean valve seat area on rear head.

2. Lubricate O-ring of new pressure relief valve and O-ring
assembly with new 525 viscosity refrigerant oil. Install
new valve and torque in place, 9.0 N*m (6.1 lbs.ft.).
4. Leak test system.
COMPRESSOR CONTROL SWITCHES
1. Recover refrigerant using J 39500-GM

2. Disconnect the electrical connector from the switch in
the rear head of the compressor (Fig. 3).
3. Remove the switch retaining ring (Fig. 3), using J 5403
internal snap ring pliers.
4. Remove switch from compressor.
5. Remove old O-ring seal from switch cavity using
1 - J 5403 SNAP RING PLIERS J 9553-01 O-ring removal tool or equivalent.
2 - SEAL RETAINER RING
NOTICE: If existing switch will be reinstalled in
compressor, a new O-ring seal must be used and
preferably a new retainer ring should also be used. A new
switch kit has the O-ring and retainer ring included.
Retaining Ring
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.
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
1 - SHAFT SEAL O-RING 1 - J 23128-A SEAL REMOVER

2 - J 9553-01 O-RING REMOVER AND INSTALLER
2 - SEAL
Fig. 22 Removing Shaft Seal O-Ring Fig. 24 Removing Shaft Seal
COMPRESSOR CONTROL VALVE

ASSEMBLY
+ + Remove or Disconnect
1. Recover refrigerant using J 39500-GM.

2. Remove control valve retaining ring using J 5403
internal snap ring pliers.
3. Remove control valve assembly.
+ 4» Install or Connect
1. When reassembling control valve, coat O-rings with 525

viscosity refrigeration oil and push in place with thumb
pressure.
2. Using J 5403 snap ring pliers, install valve retaining ring

with high point of curved sides against valve housing. Be
sure retaining ring is properly seated in ring groove.
4. Leak test referring to “Compressor Leak Testing” in this

section.
Fig. 23 Installing Shaft Seal O-Ring

4. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make
certain the leak has been corrected.
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.
1 — J 5403 SNAP RING PLIERS 15 — J 33017 PULLEY & BEARING ASSEMBLY

INSTALLER
2 — J 6083 SNAP RING PLIERS
16 — J 39500-GM R134a A/C REFRIGERANT RECOVERY,
3 — J 8092 DRIVER HANDLE
4 — J 8433-1 PULLER BAR SYSTEM (ACR4)
5 — J 8 4 3 3 -3 FORCING SCREW 17 — J 33019 BEARING STAKING TOOL
6 — J 9393- A SEAL SEAT INSTALLER 18 — J 33020 PULLEY PULLER
7 — J 9398- A BEARING REMOVER 19 — J 34614 SHAFT SEAL PROTECTOR
8 — J 9481 - A BEARING INSTALLER 20 — J 33022 SHAFT NUT SOCKET
9 — J 9553-01 O-RING REMOVER 21 — J 33023 - A PULLER PILOT
l O - J 39893 PRESSURE TESTING CONNECTOR 22 — J 33024 CLUTCH COIL INSTALLER
ll — J 2 3128-A SEAL SEAT INSTALLER & 23 — J 33025 CLUTCH COIL PULLER LEGS
REMOVER
24 — J 34992 COMPRESSOR HOLDING FIXTURE
12 — J 21352—A SUPPORT BLOCK
25 — J 33027 -A CLUTCH HUB HOLDING TOOL
13 — J 33011 O-RING INSTALLER
26 — J 39400 LEAK DETECTOR
14 — J 33013-B HUB & DRIVE PLATE REMOVER
AND INSTALLER 27 — J 39037 HIGH-SIDE CHARGE VALVE SOCKET
Fig. 27 V5 Compressor — Special Tools

BLANK
- ■■--s■ ■
■
SD-7H15 AIR CONDITIONINQ COMPRESSOR 1D4-1
SECTION 1D4
SD-7H15 AIR CONDITIONING

COMPRESSOR
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. 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....................................................................................................................................................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:
Check around the shaft seal, front housing seal,

valve plate, and oil plug. If a leak is found, replace
Figure 1—Date Code the compressor.
1D4-2 SD-7H15 AIR CONDITIONING COMPRESSOR
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.
Figure 2—Removing the Nut

Figure 5—Removing the Rotor Pulley
B. Thumb tighten the three puller bolts into the

threaded holes.
C. Turn the center bolt to the right with the socket
wrench until the front plate is loosened.
3. External front housing snap ring with J 6435 (figure
4).
4. Rotor pulley assembly.
A. Insert J 37828 into the groove (figure 5).
B. Insert J 37827 over the exposed shaft.
C. Align the thumb head bolts of J 8433 to the
puller fingers and tighten.
D. Turn the puller center bolt to the right with a
socket wrench until the rotor pulley is free (fig
ure 6).
5. Clutch coil.
A. Loosen the coil lead wire from the clip on top of
the compressor front housing.
B. Remove the snap ring (figure 7).
C. Remove the coil.
SD-7H15 AIR CONDITIONING COMPRESSOR 1D4-3
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 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.)
FASTENER TIGHTENING SPECIFICATIONS

Oil Filler Plug.................................................................................................................................................. 8 N m (71 lbs. in.)
Shaft Nut......................................................................................................................................................14 N m (124 lbs. in.)
T3036
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
POWER STEERING GEAR

UNIT REPAIR
NOTICE: Repair the steering gear in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage
the machined surfaces and result in leaking or damage to the steering gear assembly. If broken components or foreign
materials are found while disassembling the gear, the hydraulic system should be disassembled, inspected, cleaned, and
flushed. In some instances, “power steering hydraulic fluid” will be specified to lubricate parts upon assembly. In
these cases, GM hydraulic fluid should be used. Do not use brake fluid, automatic transmission fluid, or other non
approved fluids.
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: 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
Specifications ...................................................................... .... 3B1A-28

Fluid Specification ................................................................ 3BIA-28
Fastener Tightening Specifications ...................... ... 3BIA-28
Adjustment Tightening Specifications ............... ... 3B1 A-28
Special T o o ls ...................................................... ... 3B1A-29
N otes.................................................................... ... 3B1A-30
3B1A-2 POWER STEERING GEAR UNIT REPAIR
Figure 1 708 Power Steering Gear

KEY NO. PART NAME KEY NO. PART NAME

1 - RING, RETAINING 33 - WASHER, BACKUP
2 - PLUG 35- RING, RETAINING
3 - SEAL, O-RING 36 - WASHER, LOCK
5 - RING, TEFLON 37 - NUT
6 - SEAL, O-RING 38 - SEAL
7 - COVER, SIDE 40 - SHAFT, STUB
8 - NUT, ADJUSTER LOCK 41 - SPOOL, VALVE
1 0 - BOLT 42 - SEAL
11 - GASKET 43 - BODY, VALVE
12 -SHAFT, PITMAN 45 - SEAL, O-RING
1 3 -SHAFT, WORM 46- RING
1 5 - RACE 47 - SPACER
16- BEARING, THRUST 48 - NUT, ADJUSTER PLUG LOCK
1 7 - RACE 50- RING, RETAINING
1 8 -VALVE, CHECK 51 - SEAL, DUST
20- HOUSING 52 - SEAL, LIP
21 - SCREW 53 - BEARING, NEEDLE
22 - CLAMP 55 - PLUG,ADJUSTER
23 - GUIDE, BALL 56 - SEAL, O-RING
25 - BALLS 57 - RACE
26 - PISTON, RACK 58 - BEARING, THRUST
27 - PLUG 60 - RACE
28 - BEARING, NEEDLE 61 - SPACER, BEARING
30 - SEAL, SINGLE LIP 62- RETAINER, BEARING
31 - WASHER, BACKUP 63 - SEAL, PITMAN SHAFT
32 - SEAL, DOUBLE LIP 64 - SEAL, DUST (CK, L ONLY)
33 - WASHER, BACKUP 65 - BOOT, PITMAN SHAFT (CK, L ONLY)
Figure 2 708 Power Steering Gear - Legend
STEERING GEAR ADJUSTMENTS WORM THRUST BEARING PRELOAD

ADJUSTMENT
Important Figures 1 thru 6
• Before any adjustments are made on the steering Tool Required:
gear, refer to “Steering, Suspension, Tires and J 7624 Spanner Wrench
Wheels Diagnosis” (Section 3) for reviewing the
possible steering system problems. Any steering 1. Remove steering gear from vehicle. Refer to
gear adjustment is made only as a correction and not “Power Steering Gear Replacement” in Section 3B.
as a periodic adjustment. 2. Rotate stub shaft (40) back and forth to drain power
For proper adjustment, remove the steering gear from the steering fluid.
vehicle. Drain the power steering fluid from the gear. 3. R em ove a d ju s te r plug lock nut (48) from
M ount the gear in a vise and make the follow ing housing (20).
adjustments. Notice: Be careful not to cause any burrs on the back face
The steering gear requires two adjustments: of the locknut during removal. A burr on the locknut can
• The worm thrust bearing preload affect valve alignment and steering effort.
• The pitman shaft over-center preload adjustment Notice: See “Notice” on page 3B1 A-1 of this section.
The worm thrust bearing preload is controlled by the
amount of compression force exerted by the adjuster plug 4. Turn adjuster plug (55) in (clockwise) using J 7624
on the conical worm bearing thrust races. until adjuster plug (55) and thrust bearing (58) are
firmly bottomed in housing (20).
The pitman shaft over-center preload is controlled by the
pitman shaft adjuster screw, which determines the clear
ance between the rack piston and the pitman shaft Tighten
sector teeth.
• Adjuster plug (55) to 30 N*m (22 lb. ft.).
Important Place an index mark on housing (20) even with one
of the holes in the adjuster plug (55).
Adjust the worm thrust bearing preload first, then
adjust the pitman shaft over-center preload.
6. Measure back counterclockwise 13 mm (1/2 inch) PITMAN SHAFT OVER-CENTER PRELOAD

and place a second mark on housing (20). ADJUSTMENT
Figures 7 thru 9
7. Turn adjuster plug (55) counterclockwise until hole
in adjuster plug (55) is aligned with the second mark 1. Remove steering gear from vehicle. Refer to
on the housing (20) (see Figure 6). “Power Steering Gear Replacement” in Section 3B.
8. Install adjuster plug lock nut (48). 2. Rotate stub shaft back and forth to drain power
steering fluid.
3. Loosen the adjuster lock nut (8).
Tighten
H 4. T urn the p itm an sh a ft a d ju s te r screw
counterclockwise until fully extended, then turn
Adjuster plug lock nut (48) to 109 N*m
clockwise 1 full turn.
(80 lb. ft.) using a drift in a notch.
5. Rotate the stub shaft (40) from stop to stop, using a
• H old a d ju s te r plug (55) to m aintain
12-point socket, and count the number of turns.
alignment of the marks.
6. Starting at either stop, turn the stub shaft (40) back
9. Install steering gear. Refer to “Power Steering Gear 1/2 the total number of turns. This is the “center” of
Replacement” in Section 3B. the gear.
• When the gear is centered, the flat on the stub
shaft (40) should face upward and be parallel
with the side cover (7) and the master spline
on the pitman shaft should be in line with the
adjuster screw (see Figure 8).
7. Place a torque wrench on the stub shaft (40) with
the handle in the vertical position. Rotate the stub
shaft (40) 45T each side of the center (see Figure 9).
• Stub shaft must rotate smoothly and must not
stick or bind.
• Record the worm bearing preload measured
on or near the center.
• Recorded bearing preload to be 0.7-1.7 N*m
(6-15 lb. in.), with worm and ball nut
installed. If the torque is outside this range,
the gear assembly should be readjusted or
repaired as required.
Notice: See “Notice” on page 3B1 A-l of this section.

40 - SHAFT, STUB
48 - NUT, ADJUSTER PLUG LOCK
Figure 3 Loosening Adjuster Plug Nut
A-INDEX MARK
5 5 -PLUG, ADJUSTER B-SECOND INDEX MARK
Figure 4 Marking Housing Even with Adjuster Plug Figure 5 Remarking the Housing
STEERING GEAR SERVICE

Adjust
PITMAN SHAFT AND SIDE COVER
Over-center torque by turning the pitman shaft ad REPLACEMENT
juster screw clockwise until the correct preload Figures 1 and 2
torque is obtained.
Add 0.7-1.1 N*m (6-10 lb. in.) torque to the Remove or Disconnect
previously measured worm bearing preload torque.
Steering gear from vehicle. Refer to “Power Steer
ing Gear Replacement” in Section 3B.
Pitman arm from steering gear. Refer to “Steering
• Adjuster lock nut (8) to 49 N«m (36 lb. ft.). Linkage” in Section 3B3.
• Prevent adjuster screw from turning while Rotate stub shaft back and forth to drain power
tightening adjuster lock nut (8). steering fluid.
8. Install steering gear. Refer to “Power Steering Clean

Gear Replacement” in Section 3B.
• Exposed end of pitman shaft and housing.
• Use a wire brush to clean pitman shaft spline.
Figure 8 Aligning Pitman Shaft Master Spline
7 -COVER, SIDE
4 0 -SHAFT, STUB
Figure 7 Aligning the Stub Shaft

HOUSING END PLUG REPLACEMENT

Disassemble Figure 10
m
1. Adjuster lock nut (8).
2. Bolts (10). Remove or Disconnect
• Rotate stub shaft (40), using a 12-point socket,
to center gear. Steering gear from vehicle. Refer to “Power
3. Side cover (7), gasket (11), and pitman shaft (12) as Steering Gear Replacement” in Section 3B.
an assembly.
4. Pitman shaft (12) from the side cover (7). Disassemble
*
Rotate stub shaft back and forth to drain fluid.
Assemble
£
Notice: See “Notice” on page 3B1 A-l of this section. 1. Retaining ring (1) by using a punch inserted into the
housing access hole to unseat it.
1. Pitman shaft (12) to side cover (7) by screwing 2. Plug (2).
pitman shaft (12) in until it fully seats to side 3. O-ring seal (3).
cover (7).
2. Adjuster lock nut (8). * Assemble
• Do not tighten adjuster lock nut (8) until after
• Lubricate O-ring seal with power steering fluid.
pitman shaft adjustment has been made.
3. Gasket (11) to side cover (7) and bend tabs around
1. O-ring seal (3) into housing (20).
edges of side cover (7).
2. Plug (2).
4. Pitman shaft assem bly and side cover (7) to
3. Retaining Ring (1).
housing (20).
• Install retaining ring (1) so that open end is
5. Bolts (10).
approximately 25 mm (1 inch) from access
hole in housing (20).
HI Tighten
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.
Figure 10 Housing End Plug Figure 11 Removing Adjuster Plug

ADJUSTER PLUG ASSEMBLY

REPLACEMENT ❖ Assemble
Figures 1,2, 11 thru 14 • Position adjuster plug (55) face up on a suitable
Tools Required: support.
J 7624 Spanner Wrench Notice: N eed le b earin g m ust be in sta lle d with
J 6221 Adjuster Plug Bearing Remover and identification on bearing facing tool to prevent damage to
Installer bearing.
Remove or Disconnect Needle bearing (53) to adjuster plug (55) using

J 6221.
Steering gear from vehicle. Refer to “Power 2. Lip seal (52) to adjuster plug (55) using J 6221.
Steering Gear Replacement” in Section 3B. 3. Dust seal (51) to adjuster plug (55) using J 6221.
4. Retaining ring (50).
❖ Disassemble 5. O-ring seal (56) to adjuster plug (55).
• Lubricate O-ring seal (56) with white petro
1. Adjuster plug lock nut (48) from housing (20). leum grease (not power steering fluid) to
2. Adjuster plug (55) from housing (20) using J 7624. prevent rolling and cutting.
6. Large bearing race (57), thrust bearing (58), small
9 Important bearing race (60) and bearing spacer (61) to adjuster
plug (55).
Do not move or rotate valve stub shaft (40)
while adjusterplug is removed. Any rotation
of the stub shaft may cause balls (25) to be
lost from the gear circuit requiring complete
tear down of the unit.
3. Thrust washer bearing retainer (62) from adjuster
plug (55) by using a screwdriver to pry at raised area
of bearing retainer (62).
4. Bearing spacer (61), races (57 and 60) and thrust
bearing (58).
5. O-ring seal (56).
• Position adjuster plug (55) face down on a
suitable support (see Figure 13).
7. Needle bearing (53), dust seal (51) and lip seal (52)
using J 6221 to drive them from adjuster plug (55).
A-SCREWDRIVER
5 3 -BEARING, NEEDLE
6 2 -RETAINER, BEARING
Figure 12 Removing Bearing Retainer

7. Thrust washer bearing retainer (62) to adjuster

Install or Connect
plug (55).
• Lubricate lip of seals (51 and 52) with white • Power steering gear. Refer to “Power Steering
petroleum grease (not power steering fluid) Gear Replacement” in Section 3B.
to prevent cutting during adjuster plug (55)
installation. VALVE REPLACEMENT
Notice: Pack the small cavity between seals (51 and 52) Figures 1, 2, 15 thru 18
with white petroleum grease before installing adjuster plug
(55). When installing adjuster plug, be careful not to cut the
seals. Remove or Disconnect
8. Adjuster plug (55) to housing (20) using J 7624. Steering gear from vehicle. Refer to “Power
Steering Gear Replacement” in Section 3B.
Adjust
0 Disassemble
*
Thrust bearing preload. Refer to “Worm
1. A djuster plug (55). Refer to “A djuster Plug
Thrust Bearing Preload A djustm ent” in
Assembly Replacement” in this section.
this section.
2. Stub shaft (40) and valve assembly.
9. Install adjuster plug lock nut (48), and using a drift 9 Important
in a notch, tighten securely.
• H old a d ju s te r plug (55) to m aintain • Do not move or rotate worm shaft (13) while
alignment of the marks. valve assembly is removed. Any rotation of
the worm shaft may cause balls (25) to be lost
Adjust from the gear circuit requiring complete tear
down of the unit.
Pitman shaft over-center sector. Refer to 3. Stub shaft (40) from valve assembly, if necessary.
“P itm an S h aft O v e r-C e n te r P relo ad • Tap stub shaft (40) lightly on a wood block to
Adjustment” in this section. loosen shaft cap.
• Pull cap and valve spool (41) out from valve
body (43) 6 mm (1/4 inch) and disengage
stub shaft pin from hole in valve spool (41).
4. Valve assembly, if necessary.
• Remove valve spool (41) by pulling and
rotating from valve body (43).
• Remove valve spool O-ring seal (42).
• Remove valve body teflon rings (46) and
O-ring seals (45).
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
3. Stub shaft (40) and valve assem bly to worm

❖ Assemble shaft (13), fitting pin on worm shaft ( 13) to slot in the
valve assembly.
1. Valve assembly, if necessary. 4. Adjuster plug. Refer to “Adjuster Plug Assembly
• Install valve spool O-ring seal (42) to valve
Replacement” in this section.
spool (41).
• Lubricate valve spool (41) and O-ring Adjust
seal (42) with power steering fluid.
• Install valve spool (41) to valve body (43) by • Thrust bearing preload and pitman shaft
pushing and rotating until hole in valve over-center sector. Refer to “Steering Gear
spool (41) for stub shaft pin is accessible Adjustments” in this section.
from opposite end of valve body (43).
Stub shaft (40) to valve spool, if necessary and Install or Connect
insert pin.
Steering gear. Refer to “Power Steering Gear Re
• Notch in stub shaft cap must fully engage
valve body pin and seat against valve body placement” in Section 3B.
shoulder.
• Install O-ring seals (45) and teflon rings (46)
to valve body (43).
• Lubricate O-ring seals (45) and teflon
rings (46) with power steering fluid.
Figure 17 Remove and Install Spool

RACK PISTON AND WORM SHAFT Clean

REPLACEMENT
Figures 1,2, 19 thru 22 All disassembled parts.
Tools Required:
J 8947 Rack Piston Teflon Ring Compressor Z° Inspect
J 21552 Rack Piston Arbor
• All disassembled parts for wear. Replace if
Remove or Disconnect necessary.
Steering gear from vehicle. Refer to “Power Steering * Assemble

Gear Replacement” in Section 3B.
O-ring seal (6) and teflon ring (5) and lubricate with
❖ Disassemble power steering fluid.
2. Worm shaft (13) to rack piston (26) outside of
Tool Required: housing (20).
J 21552 Rack Piston Arbor
l. Pitman shaft and side cover. Refer to “ Pitman Shaft • Fully seat worm shaft (13) to rack piston (26)
and Side Cover Replacement” in this section. and align worm shaft spiral groove with rack
2. Housing end plug. Refer to “Housing End Plug Re piston ball return guide hole (see Figure 20).
placement” in this section. 9 Important
• Turn stub shaft counterclockwise until the
rack piston (26) begins to come out of the • Make sure that all rack piston balls (25) are
housing (20). reinstalled in the rack piston. Improper rack
3. Rack piston plug (27). piston ball installation may result in personal
• Insert J 21552 into bore of rack piston (26). injury.
Hold J 21552 tightly against worm shaft while
turning the stub shaft counterclockwise.
Notice: The black rack piston balls are smaller than the
silver balls. The black and silver balls must be installed
• The rack piston (26) will be forced onto
alternately into the rack piston and ball guide to maintain
J 21552 and hold the rack piston balls (25) in
rack piston to worm shaft preload.
place.
4. Rack piston (26), rack piston balls (25), and J 21552 • Lubricate rack piston balls (25) with power
together from housing (20). steering fluid.
5. Valve. Refer to “Valve Replacement” in this section. 3. Rack piston balls (25) to rack piston (26) by
6. Worm shaft (13). inserting through ball return guide hole while
7. Thrust bearing (16) and races (15 and 17). turning worm shaft (13) counterclockwise.
8. J 21552 from rack piston (26). 4. Remaining rack piston balls (25) to ball guide (23)
9. Rack piston balls (25). using grease at each end to retain balls (25)
10. Screws (21), clamp (22) and ball guide (23). (see Figure 21).
11 . Teflon ring (5). 5. Ball guide (23) to rack piston (26).
12 . O-ring seal (6).
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
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
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
1. Pitman shaft boot (65) (C/K only).
Notice: Use care not to score the housing bore when

prying out seals and washers.
2. Pitman shaft dust seal (64) using a screwdriver to
pry it from the housing (20).
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
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.
Assemble • Check valve (18) by prying from housing with a

* small screwdriver.
C/K-Truck, L-Van
❖ Assemble
• Coat lips of pitman shaft seal (63) and dust seal (64)
with white petroleum grease. • Check valve ( 18) using a 3/8-inch diameter piece of
tubing 100 mm (4 inches) long todrive into housing.
1. Needle bearing (28) to housing (20) using J 6278.
2. Pitman shaft seal (63) (cavity facing in) using
J 6219. Install or Connect
Steering gear. Refer to “Power Steering Gear
Notice: Seal (63) must not bottom against needle
bearing (28). Replacement” in Section 3B.

Figure 1 710 Power Steering Gear

Key No. Part Name Key No. Part Name

1 - NUT, PRELOAD ADJUSTER 27 - RING, VALVE BODY
2 - BOLT, HEX HEAD (SIDE COVER) 28 - BODY, VALVE
3 - COVER ASSEMBLY, HOUSING SIDE 29 - SEAL, O-RING (SPOOL)
4 - SEAL, O-RING (SIDE COVER) 30 - SPOOL, VALVE
5 - GEAR ASM., PITMAN SHAFT 31 - SHAFT, STUB
6 - HOUSING, STEERING GEAR 32 - SEAL, O-RING (STUB SHAFT)
7 - PISTON, SECONDARY RACK 33 - WORM ASM, PIN &
8 - PLUG, RACK PISTON 34 - RACE, THRUST BEARING (WORM)
9 - SEAL, O-RING (RACK PISTON) 35 - BEARING ASM, ROLLER THRUST (WORM)
10- RING, RACK PISTON 36 - RACE, THRUST BEARING (WORM)
11 - SEAL, O-RING (HOUSING) 37 - SEAL, O-RING (RELIEF VALVE)
12- PLUG, HOUSING END 38 - PLATE, BYPASS
13 - RING, RETAINING (HOUSING END PLUG) 39 - SEAL, O-RING (RELIEF VALVE)
14 - NUT, ADJUSTER PLUG LOCK 4 0 - VALVE ASM, RELIEF
15- RING, RETAINING 41 - SEAL, PITMAN SHAFT DUST
16 - SEAL, STUB SHAFT DUST 42 - RING, RETAINING (PITMAN SHAFT SEAL)
1 7 -SEAL, STUB SHAFT 43 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
18 - BEARING ASM., NEEDLE 44 - SEAL, PITMAN SHAFT
1 9 - PLUG,ADJUSTER 45 - BEARING ASM, NEEDLE (PITMAN SHAFT)
20 - SEAL, O-RING ADJUSTER 4 6 -GUIDE, BALL RETURN
21 - RACE, UPPER THRUST BEARING (LARGE) 47 - CLAMP, BALL RETURN GUIDE
22 - BEARING ASM, UPPER THRUST 48 - SCREW ASM, LOCKWASHER
23 - RACE, UPPER THRUST BEARING (SMALL) 49 - BALLS
24 - SPACER, THRUST BEARING 50 - PISTON, (RH) PRIMARY RACK
25 - RETAINER, BEARING (ADJUSTER) 51 - CONNECTOR, INVERTED FLARE
26 - SEAL, O-RING (VALVE BODY)
Figure 2 710 Power Steering Gear - Legend
GEAR DISASSEMBLY
Figures 1 thru 9
Tools Required:
J 2 1552 Rack Piston Arbor
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
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
If secondary cylinder plug (12) was forced

out of housing (6) during step 3, proceed to
step 8.
• Turn stub shaft (31) clockwise until rack

piston (50) bottoms in housing (6).
• Align the end tooth of the pitman shaft (5)
with the center groove of the rack piston (50)
and (7) (see Figure 7).
• Turn stub shaft (31) counterclockwise until
the plug (12) separates from the housing (6).
8. Secondary rack piston (7) (see Figure 7).
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
9. Rack piston (50) and balls (49).

10. Pitman shaft (5) from housing (6). Tap in end
of shaft.
11. Nut (14) (see Figure 8).
12. Adjuster plug (19). Use tool J 7624 or equivalent
(see Figure 9).
13. Valve (28) and worm shaft (33) as an assembly with
both races (34) and bearing (35).
14. Worm shaft (33) from valve assembly.
15. Races (34) and bearing (35) from worm shaft (33).
Im portant
Do not attempt to reuse damaged or worn

p arts by w eld in g or having them
straightened. Replace all bent, broken or
worn parts.
Clean
* All parts in a clean solvent and blow dry.
A-HAM MER
B-D R IFT
14 - NUT, ADJUSTER PLUG LOCK
Figure 8 Loosening Adjuster Plug Lock Nut
1 9 -PLUG,ADJUSTER
31 - SHAFT, STUB
Figure 9 Adjuster Plug Removal

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).
• If the seal (17) is to be replaced, install the

adjuster plug (19) loosely in the gear hous
ing.
1. Retainer ring (15) (see Figure 10).
2. Dust seal (16).
3. Seal (17). Pry with a screwdriver from the bore of
the adjuster plug (19). Do not scratch or score the
seal bore (see Figure I I).
Figure 10 Retaining Ring Removal
17
19
Figure 11 Stub Shaft Seal Removal Figure 13 Needle Bearing Removal

Inspect
Spacer (24) for wear or cracks.

Races (23, 21) for wear or scoring.
Adjuster plug (19) threads for wear.
Bearing (22) for wear or scoring.
Needle bearing (18) for wear, pitting, or
scoring (see Figure 14). R eplace if
necessary.
“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).
A - BEARING WITH IDENTIFICATION

TOWARDS TOOL
B-W O O D BLOCK
Figure 15 Needle Bearing Installation
1 7 -SEAL, STUB SHAFT
Figure 14 Needle Bearing Inspection Figure 16 Stub Shaft Seal Installation

3. Dust seal (16).

4. Retaining ring (15), use tool J 4245 (see Figure 17).
• Lubricate new seal (20) with power steering
fluid.
5. New seal (20).
• Lubricate the thrust bearing assembly with
power steering fluid.
6. Large race ( 2 1) on the adjuster hub.
7. Bearing (22).
8. Small race (23).
9. Spacer (24) with the grooves of the spacer away
from small race (23) (see Figure 18).
10. New bearing retainer (25). Tap on the flat surface of
the retainer (see Figure 19).
9 Im portant
The retainer projections must not extend

beyond the spacer when the retainer is seated.
The spacer must be free to rotate.
22 - BEARING ASM., UPPER THRUST

23 - RACE, UPPER THRUST BEARING (SMALL)
24 - SPACER, THRUST BEARING
Figure 18 Spacer and Race Placement
16-SEAL, STUB SHAFT DUST A-PUNCH

15-RING, RETAINING 2 5 -RETAINER, BEARING
Figure 17 Retaining Ring Installation Figure 19 Bearing Retainer Adjuster Installation

VALVE AND STUB SHAFT

Figures 20 thru 25
Important
Valve assembly malfunction is uncommon,
except during seal replacement. Do not
service the valve unless indicated to do so.
♦ Disassemble
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
A ssem ble
• Lubricate new rings (27) and seals (26).

1. New seals (26) in the ring grooves.
2. New rings (27) in the grooves over the seals (26).
• Lubricate valve spool seal (29).
3. Seal (29) over the valve spool.
• Lubricate the valve spool and the valve
body (28).
Valve spool into the flush end of the valve body (28)
(see Figure 21).
• Rotate the valve spool while pushing it
into the valve body. Push until the shaft
pin hole is visible from the opposite end
(see Figure 24).
• Lubricate the stub shaft (31) assembly.
5. Stub shaft (31) assembly into the valve spool
until the shaft pin can be placed into the valve spool
(see Figure 22).
• Align the notch in the shaft cap with the pin
in the valve body (28).
9 Im portant
Make sure that the shaft cap notch is mated

with the valve body pin before installing the
valve body into the gear assembly.
Valve spool and shaft (31) assembly into the valve

body (28). The shaft cap should be below the valve
body notch (see Figure 25).
• Lubricate a new shaft cap to the seal (32).
7. New shaft cap and seal (32) into the valve body (28)
assembly.
PITMAN SHAFT AND SIDE COVER

Figure 1
Z° Inspect
Bearing in side cover (3). Needles should

rotate freely using finger pressure. Replace
bearing and side cover (3) if necessary.
Bearings’ surface in the side cover (3) for
scoring. Replace side cover assembly if
necessary.
Sealing and bearing surfaces of the pitman
shaft (5) for roughness, nicks, or other dam
age. Replace pitman shaft assembly if
necessary.
Pitman shaft (5) for excessive wear or
scoring. Check sector gear teeth for wear.
R eplace the pitm an shaft assem bly if
necessary.
Pitman shaft (5) adjuster screw threads for
wear. The adjuster screw must be free to turn
with no end play.
PRIMARY RACK PISTON

Figure 1 and 29
Tool Required:
J 21552 Rack Pinion Arbor
Inspect
1. W orm (33) and rack piston (50) grooves and all balls
(49) for scoring. Replace as a matched assembly.
2. Seal (9) and ring (10) for wear.
3. Ball return guide halves (46) for cracks and damage.
4. Bearing (35) and races (34) for scoring and exces
sive wear.
5. Rack piston (50) teeth and external ground surfaces
for scoring or excessive wear. If condition exists,
replace the rack piston (50) and worm (33).
Assemble
l. New Seal (9) and ring (10) to rack piston (50).
• Lubricate new seal (9) and ring (10) with
A-INSTALL BALLS IN THIS 4 6 -GUIDE, BALL

HOLE WHILE SLOWLY RETURN
ROTATING WORM 4 7 -CLAMP
COUNTERCLOCKWISE 4 8 -SCREWS 3 3 -SHAFT, WORM
B-WORM FLANGE 49 - BALLS 50 - PISTON, (RH) PRIMARY RACK
STEERING GEAR CONNECTORS PITMAN SHAFT BEARING AND

Figure 1 and 29 SEAL REPLACEMENT
Figure 30
Tool Required:
J 6217 Valve Connector Seat Installer Tools Required:
J 4245 Internal Snap Ring Pliers
9 Important J 24655 Bearing Installer and Remover
J 8092 Handle
Do not perform the following procedure
with the valve assem bly installed in the
gear housing. NOTICE: When removing seals, be careful not to score
the housing bore or leakage may result.
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).
GEAR REASSEMBLY
Figures 31 thru 39 J 24655
Tool Required:
J 6222-A Shaft Seal Protector
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).
NOTICE: See “Notice” on page 1 of this section.

• Install the nut (14) and torque to 108 N*m
(80 lb. ft.). Hold the adjuster plug to
maintain alignment on the hole with the mark.
• Check the turning torque using a 3/4" A -P IN
12-point socket and an inch-pound torque B -S LO T
wrench. Use tool J 7754-01 (see Figure 36). 2 8 -BODY, VALVE
3 3 -SHAFT, WORM
Figure 33 Notch and Pin Alignment

• Push rack piston (with teeth toward pitman

shaft openings) into the housing until the
tool contacts the center of the worm.
• Turn the stub shaft (3 1) clockwise to thread
the rack piston onto the worm (33) while
holding tool J 2 1552 against the end of the
worm.
• Remove tool J 2 1552 after the rack piston is
completely threaded on the worm.
• Center the rack piston in the side cover
opening.
4. Secondary rack piston (7) in the housing (plug out,
teeth toward shaft opening).
• Align rack piston teeth with the primary
teeth.
5. Pitman shaft (5) and the side cover (3).
• Lubricate area between the seal lips of the
pitman shaft seal with chassis lubricant or an
all-purpose grease.
• Slide pitman shaft into place.
NOTICE: The pitman shaft must be installed with

the tapered teeth engaging the primary rack piston
(see Figure 37). If this procedure is not followed, it will be
impossible to eliminate lash between the primary gear
teeth.
• Install a new seal (3) on the side cover and
lubricate with power steering fluid.
• Push the side cover (3) into the housing (6)
until the adjuster screw on pitman shaft (5)
contacts the cover.
• Insert a hex wrench through the cover into
the a d ju ste r screw and turn it
counterclockwise until the cover bottoms on
the housing. Then back off 1/2 turn.
• Preload adjuster prevailing torque nut ( l ) on
the adjuster screw.
NO TICE: See “ N otice” on page I o f this section.

• Install the side cover bolts (2) and torque to
47 N*m (35 lb. ft.).
6.
Plug (8) both cylinders.
Tighten
• Plugs (8) to l02N*m (75 lb. ft.) if aluminum,

or I 15 N*m (85 lb. ft.) if steel.
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
Figure 35 Re-marking the Housing

Pitman shaft preload, as follows (see Figure 39):

1. Attach tool J 7754-01 and a 12-point socket on the
stub shaft splines.
2. Center the steering gear by:
• Counting the number of turns while turning
the stub shaft (31) counter-clockwise until
bottomed.
• Turn the shaft back half the number of turns
counted above to centered position.
3. Check the combined ball and bearing preload by
turning the torque wrench through the center of
travel and recording the highest reading.
4. Tighten the adjusting screw on pitman shaft (5)
until the torque wrench reading is 0.7-1.1 N*m
(6-19 lb. in.) higher than the reading recorded in
step 3. Figure 37 Pitman Shaft Gear Teeth
• The total read in g should not exceed
2.25 N«m (20 lb. in.) torque.
NOTICE: See “Notice” on page 1 of this section.

5. Tighten the nut (1) to 90 N*m (66 lb. ft.).
6. Recheck the preload after tightening the nut (1).
J 7754-01
B - 1/4 INCH HEX

19-PLUG,ADJUSTER 1 - NUT
Figure 36 Checking the Bearing Preload Figure 39 Over Center Preload Adjustment
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
o r E quivalent m eeting G M S pecification 9985010.
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
708 Pow er Steering G ear

(8) Steering Gear Adjuster Lock N u t ............................................................................................49 N«m (36 lb. ft.)
(21) Rack Piston Guide Clamp S crew .............................................................................................58 N*m (43 lb. ft.)
(27) Rack Piston P lu g ...................................................................................................................... 150 N*m (111 lb. ft.)
(48) Adjuster Plug Lock N u t.......................................................................................................... 109 N*m (80 lb. ft.)

(1) Pitman Shaft Preload Adjuster Screw Jam N u t.....................................................................90 N*m (66 lb. ft.)
(2) Side Cover B o lts ........................................................................................................................ 47 N*m (35 lb. ft.)
(8) Rack Piston Plug:
A lum inum ................................................................................................................................. 102 N*m (75 1b. ft.)
S te e l........................................................................................................................................... 115 N*m (85 lb. ft.)
(14) Adjuster Plug Lock N u t.......................................................................................................... 108 N*m (80 lb. ft.)
(19) Adjuster Plug and
(22) B earing.........................................................................................................................................27 N-m (29 lb. ft.)
(40) Relief V a lv e ................................................................................................................................ 47 N*m (35 lb. ft.)
(48) Lock washer S c re w s.................................................................................................................... 8 N*m (6 lb. ft.)
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

(40) Pitman Shaft Over-Center P relo ad * ............................................................................... 0.7-1.1 N*m (6-10 lb. in.)
(55) Steering Gear Adjuster P lu g .................................................................................................... 30 N*m (22 lb. ft.)
*Figure is in addition to worm shaft thrust bearing preload and valve and seal drag.

(5) Pitman Shaft Over Center Preload*
New G e a r.............................................................................................................................0.7-I.I N»m (6-19 lb. in.)
Used Gear** ....................................................................................................................... 0.5-0.6 N*m (4-5 lb. in.)
(5) Pitman Shaft Final Over Center Reading Total— Maximum
New G e a r....................................................................................................................................2.3 N*m (20 lb. in.)
Used G e a r .................................................................................................................................. 1.6 N*m (141b. in.)
(35) Worm Shaft Thrust Bearing P re lo a d .............................................................................. 0.5-1.1 N«m (4-10 lb. in.)
*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).
SPECIAL TOOLS
1. J 6219 2. J 4245 3. J 7624
4. J 8947 5. J 21552 6. J 6221
7. J 6278 10. J 34196-4

8. J 22912 9. J 24655
01
C
11. J 35509 12. J 6217 13. J 6222-A 14. J 7079-2
15. J 7754-01 16. J 8092 17. J 8524-1
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
NOTES
POWER STEERING PUMP UNIT REPAIR 3B1B-1
SECTION 3B1B
POWER STEERING PUMP

UNIT REPAIR
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number
fastener is not available, a fastener of equal size and strength (or stronger) may be used. 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
Specifications...................................................... .... 3B1B-8

Fluid Specifications....................................... .... 3B1B-8
Fastener Tightening S pecifications............ .... 3B1B-8
Special T o o ls ........................................................ .... 3B1B-8
3B1B-2 POWER STEERING PUMP UNIT REPAIR
Key No. Part Name Key No. Part Name

1 - SEAL, O-RING 17 - RING, SHAFT RETAINING
2 - VALVE ASM, CONTROL 1 8 - VANE, PUMP
3 - SEAL, O-RING 20- RING, PUMP
5 - SEAL, O-RING 21 - PLATE, PRESSURE
6 - SPRING, FLOW CONTROL 22 - SPRING, PRESSURE PLATE
7 - MAGNET 23 - PLATE, END
8 - HOUSING ASM, PUMP 25 - RING, END PLATE RETAINING
10 - SEAL, O-RING (HOUSING) 33 - FITTING ASM (CONNECTOR &)
11 - SEAL, DRIVE SHAFT 35 - SEAL, O-RING
12-SHAFT, DRIVE 36 - BOLT, PUMP MOUNTING
13- PIN, DOWEL 37 - RESERVOIR ASM
15- PLATE, THRUST 38 - CAP ASM, RESERVOIR
16- ROTOR, PUMP 40 - SEAL, O-RING (HOUSING TO STUD)
Figure 2 P Series Power Steering Pump-Legend
DRIVE SHAFT SEAL REPLACEMENT

❖ Disassemble
Figures 1 thru 3
Tool Required: Drain power steering fluid from pump.
J 22670 Shaft Oil Seal Installer 1. Bolts (36).
2 . Fitting (33) and O-ring seal (35).
Remove or Disconnect 3. Control valve assembly (2) and flow control spring
(6) from housing (8) if replacement is required.
Power steering pump from vehicle. Refer to “Power
4. Reservoir (37) from housing (8).
Steering Pump Replacement” in section 3B.
5. O-ring seals (1, 10, and 40).
6. Magnet (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.
PUMP RESERVOIR REPLACEMENT

Figure 1
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
Figure 3 Drive Shaft Seal

END PLATE AND ROTATING GROUP

Important REPLACEMENT
• Use new seals when assembling pump. Figures 1, 2 and 4
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
KEY NO. PART NAME KEY NO. PART NAME

1 - CAPSTICK ASM, RESERVOIR 16 - FITTING, O-RING UNION
2 - RESERVOIR ASM, HYD PUMP (TYPICAL) 25 - PLATE, THRUST
3 - CLIP, RESERVOIR RETAINING (LH) 26- RING, PUMP
5 - CLIP, RESERVOIR RETAINING (RH) 27 - VANE
6 - PIN, PUMP RING DOWEL 28 - ROTOR, PUMP
7 - SHAFT, DRIVE 30 - RING, SHAFT RETAINING
8 - SEAL, O-RING 31 - PLATE, PRESSURE
10 - HOUSING ASM, HYD PUMP 32 - SEAL, O-RING
11 - SEAL, DRIVE SHAFT 33 - SPRING, PRESSURE PLATE
12 - SPRING, FLOW CONTROL 35 - SEAL, O-RING
13 - VALVE ASM, CONTROL 36 - COVER, END
15-SEAL, O-RING 37- RING, RETAINING
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.).
4 4-1 Install or Connect 5. Pump assembly to vehicle, if removed.
1. Lubricate new O-ring (8) with power steering fluid.

• O-ring seal (8) to reservoir (2). DRIVE SHAFT SEAL
2. Reservoir assembly (2) to housing (10). (without disassembly of pump)
3. Retaining clips (3) and (5) to reservoir (2) and Figures 2 and 3
housing (10).
Tool Required:
4. Pump assembly to vehicle, if removed.
J 7728 Shaft Oil Seal Installer
CONTROL VALVE ASSEMBLY

Figure 1 E Remove or Disconnect
1. Pump assembly from vehicle, if necessary for
access.
B Remove or Disconnect 2. Protect drive shaft (7) with shim stock (see
Figure 2).
1. Pump assembly from vehicle, if necessary for
3. Seal (11) and discard. (Use small chisel to cut drive
access.
shaft seal.)
2. O-ring union fitting (16) and O-ring (15).
3. Control valve assembly (13). 44- Install or Connect
4. Flow control spring (12).
1. New drive shaft seal (11), lubricated with power
steering fluid, using tool J 7728 (see Figure 3).
2. Pump assembly to vehicle, if removed.
HYDRAULIC PUMP ASSEMBLY J? Adjust

Figures 1, 4 thru 7
Tool Required: Pressure plate (31).
J 7728 Shaft Oil Seal Installer Pump ring (26).
Vanes (27).
Thrust plate (25).
Disassemble Drive shaft (7).
* For scoring, pitting or chatter marks. If noted,
1 Retaining ring (37) using punch in access hole (see replace appropriate parts.
Figure 4).
In te rn a l c o m p o n e n ts o f pum p from pum p
housing (10) by gently pushing on drive shaft (7). ❖ Assemble
Components should include pressure plate subas
sembly consisting of: Lubricate new drive shaft seal (11) with power
• End cover (36). steering fluid.
• O-ring seal (35). • Drive shaft seal (11) into pump housing (10)
• Pressure plate spring (33). with tool J 7728 (see Figure 3).
• Pressure plate ( 3 1). 2. Pump ring dowel pins (6) into pump housing (10).
Drive shaft subassembly consisting of: 3. Thrust plate (25) and pump rotor (28) to drive
• Pump rotor (28). shaft (7) (see Figure 5).
• Thrust plate (25). 4. New shaft retaining ring (30) onto drive shaft (7).
• Drive shaft (7).
• Shaft retaining ring (30).
Pump ring (26) and vanes (27).
3. O-ring (32) from pump housing (10).
4. Dowel pins (6).
5. Drive shaft seal (11).
6. End cover (36), pressure plate spring (33) and
O-ring (35) from pressure plate (31).
7. Pump ring (26) and vanes (27) from drive shaft
subassembly.
8. Shaft retaining ring (30) from drive shaft (7).
9. Pump rotor (28) and thrust plate (25) from drive
shaft (7).
Clean
All parts in power steering fluid.
Dry parts.
THIS SIDE FACING UP
COUNTERBORE
FACING DRIVE
SHAFT END OF
HOUSING
A-DOWEL PIN HOLE (LARGE)

B-CROSS-OVER SLOT
26-RING, PUMP
28-ROTOR, PUMP
Figure 6 Rotor or Pump Ring Installation

5. Drive shaft subassembly into pump housing (10).

6. Vanes (27) into pump rotor (28).
7. Pump ring (26), with holes positioned correctly onto
dowel pins (6), in pump housing (10) (see Figure 6).
8. Lubricate new O-ring (32) with power steering
fluid.
• O-ring (32) into groove in pump housing
( 10).
9. Pressure plate (31).
10. Pressure plate spring (33).
11 . Lubricate new O-ring (35) with power steering
fluid.
• O-ring (35) into end cover (36). A-ACCESS HOLE
12. Lubricate outer edge of end cover (36) with power B»p r e s s
steering fluid. C-RETAINING RING OPENING
Press end cover (36) into pump housing (10). D-BOLT HOLE
13.
37-RING, RETAINING
14. Retaining ring (37) into groove in pump housing
(10), with ring opening near access hole in pump Figure 7 Retaining Ring Installation (Housing)
housing (see Figure 7).
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)
P Series Power Steering Pump

(33) Pump Fitting A ssem b ly .................................................................................................. 75.0 N»m (55 lb. ft.)
(36) Pump Mounting B o lt....................................................................................................... 58.0 N*m (43 lb. ft.)
CB Series Power Steering Pump

(16) O-ring Union F ittin g ........................................................................................................ 75.0 N*m (55 lb. ft.)
SPECIAL TOOLS
FRONT AND REAR AXLES 4-1
SECTION 4
FRONT AND REAR AXLES

CONTENTS
SUBJECT PAGE
7 5/8-Inch Ring Gear...................................................................................................................................................4B1-1
8 1/2 and 8 5/8-Inch Ring Gear................................................................................................................................4B2-1
9 1/2-Inch Ring Gear...................................................................................................................................................4B3-1
10 1/2-Inch Ring Gear.................................................................................................................................................4B4-1
Dana Model 80 Rear Axles....................................................................................................................................... 4B5-1
Locking Differentials...................................................................................................................................................4B7-1
7 1/4-Inch Ring Gear and All Wheel Drive Front A x le ......................................................................................4C1-1
8 1/4 and 9 1/4-Inch Ring Gear................................................................................................................................4C2-1
---
NOTES
1XA M a n OKA T W O '1?
ermrmo-
j5*xA m i* svhO i 'sitW IIA bm r ■
:• .
7 5/8-INCH RING GEAR 4B1-1
SECTION 4B1
7 5/8-INCH RING GEAR

CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to CAUTIONS in
Section 9J under ”ON-VEH!CLE 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.
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.
11. Differential case.

• Pry the case from the axle housing at the differ
ential “window” (figure 7).
12. Bearing outer races, shims, and spacers.
• Mark the races and the shims left and right, and
place them with the bearing caps.
13. Differential side bearings using J 8107-2 and
J 22888-20 (figure 8).
A. Axle Code
B. Axle Assembly Build Source Code • The jaws of J 22888-20 must pull from beneath
(C) Chev.-Buffalo the bearing cone and not the cage.
(K) GM of Canada 14. Ring gear bolts.
C. Day Built • Ring gear bolts have left-handed threads.
D. Shift (D = Day, N = Night)
B8110
NOTICE: Do not pry the ring gear from the
case. This will damage the ring gear and the
Figure 1—Rear Axle Identification differential case.
1. Brake Drum 19. Shim

2. Axle Shaft 20. Pinion and Ring Gear Set
3. “C ” Lock 21. Shim
4. Wheel Stud 22. Differential Side Bearing
5. Backing Plate Bolt 23. Spacer
6. Brake Assembly 24. Differential Case
7. Axle Shaft Oil Seal 25. Ring Gear Bolt
8. Axle Shaft Bearing 26. Differential Gears
9. Axle Housing 27. Pinion Thrust Washers
10. Axle Air Vent 28. Side Gear Thrust Washers
11. Pinion Nut 29. Pinion Shaft
12. Washer 30. Pinion Shaft Lock Bolt
13. Pinion Flange 31. Bearing Cap
14. Pinion Oil Seal 32. Bolt
15. Pinion Outer Bearing 33. Gasket
16. Plug 34. Cover
17. Collapsable Spacer 35. Bolt
18. Pinion Inner Bearing
F4673
Figure 2—Rear Axle Components
Figure 5— Removing the Axle Bearing
Figure 4—Axle Shaft Components Figure 6— Differential Case Components
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.
Inspect A. Press the bearing off the pinion using J 25320

!? (figure 14).
• Drive pinion bearing preload and record for use B. Remove the shim.
when reassembling the pinion (figure 9). 22. Bearing cups from the axle housing using a ham
• The pinion assembly for looseness by moving it mer and punch in the slots provided for this pur
back and forth. Looseness indicates excessive pose.
bearing wear.
16. Pinion flange nut and washer using J 8614-01 to • Work the cups out of the housing evenly, mov
hold the pinion flange (figure 10). ing the punch back and forth between one side
17. Pinion flange using J 8614-01 (figure 11). of the cup and the other.
18. Pinion from the axle housing (figure 12).
A. Thread the pinion nut halfway onto the pinion. CLEANING
B. Install the differential cover with two bolts to
keep the pinion from falling. Do not steam-clean drive parts that have ground and
C. Drive the pinion out of the housing with a ham polished surfaces such as gears, bearings, and shafts.
mer and drift. All parts should be disassembled before cleaning.
D. Remove the cover and pinion. These parts should be cleaned in a suitable solvent.
Figure 8—Removing Differential Side Bearings Figure 10— Removing/Installing the Pinion Nut.
• The bearing cup bores for nicks or burrs. Remove

Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lint free rags. Parts may be any burrs that are found.
dried with compressed air. Do not allow the bearings to • The housing for cracks. Replace the housing if any
spin while drying them with compressed air. cracks are found.
• The housing for foreign material such as metal
INSPECTION chips, dirt, or rust. Refer to “Cleaning."
It is critical to carefully and thoroughly inspect all DIFFERENTIAL

drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or Inspect
L9
stress and subsequent replacement of worn parts will
eliminate costly drive component repair after reassem
• Pinion gear shaft for unusual wear.
bly.
• Pinion gear and side gear teeth for wear, cracks,
AXLE HOUSING scoring, and spalling.
• Thrust washers for wear.
L1 Inspect • The fit of the side gears in the differential case.
• The fit of the side gears on the axle shafts.
The axle housing bore for nicks or burrs that could • 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.
J 8 6 1 4 -3
Figure 11— Removing the Pinion Flange Figure 13—Pinion Collapsible Spacer
PINION AND RING GEAR Important
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.
Ring gear and pinion gear for wear and replace

them as a set if worn.
ASSEMBLY OF THE REAR AXLE
"►4- Install or Connect (Figures 2 and 15 through
Important
33)
• Low m ileage bearings may have very small Tools Required:

scratches and pits on the rollers and the bearing J 29710 Differential Side Bearing Installer
cups from the initial preload. Do not replace a J 7818 Rear Pinion Bearing Cup Installer
bearing for this reason. J 7817 Front Pinion Bearing Cup Installer
SHIMS •Pinion bearing cups using J 29710, J 7818, and
J 8092.
13 Inspect PINION DEPTH ADJUSTMENT
Tools Required:
• Shims for cracks and chips. Damaged shims J 21777-40 Rear Pilot Washer
should be replaced with an equal size service J 21777-42 Front Pilot Washer
shim. J 21777-43 Stud Assembly Bolt
J 21777-45 Side Bearing Discs
J 23597-1 Arbor
J 23597-11 Gage Plate
J 8001 Dial Indicator
Figure 16— Installing the Rear Pinion Bearing Cup Figure 18—Checking Pinion Depth
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
+«- Install or Connect (Figures 2, 19, and 20)
Tools Required:
J 25299 Differential Side Bearing Installer
Plug
10. Differential side bearings using J 25299, J 8092,

and J 8107-2 (figure 20).
• Place J 8107-2 in the differential case on the
side opposite of bearing installation to protect
the differential case.
• Drive the bearing onto the case using J 25299
and J 8092.
11. Differential case to the axle housing. Refer to "Side
Bearing PreLoad Adjustment."
SIDE BEARING PRELOAD ADJUSTMENT

(Figures 2, 21, 22, and 23)
Tool Required:
J 22779 Side Bearing Backlash Gage
• The differential side bearing preload adjustment
must be made before installing the pinion.
• The differential case side bearing preload is adjust
ed by changing the thickness of the left and right
shims equally. This procedure will maintain the
original backlash.
• Production shims are cast iron and are not to be 3. Move the tool back and forth in the bore while
reused. Measure the production shims and spacers turning the adjusting nut to the right until a notice
one at a time and add the measurements together able drag is produced (figure 22).
to obtain the sizes of the left and right shim packs. A. Tighten the lock bolt on the side of the tool.
• Service spacer thickness is nominal at 4.32 mm B. Leave the tool in place.
(0.170 inch). 4. Install a service spacer and service shim between
• Service shims are available from 1.02 mm to 2.54 the right bearing cup and axle housing.
mm (0.040 to 0.100 inch) in increments of 0.101 5. Determine bearing preload by inserting progres
mm (0.004 inch). sively larger feeler gage sizes between the axle
• Make sure the side bearing surfaces are clean and housing and service shim.
free of burrs. A. Push the feeler gage downward so it contacts
the shim at the top and bottom, and then con
1. Place the case with the bearing cups installed into tacts the axle housing.
the axle housing. B. The point just before additional drag begins is
A. Lubricate the axle bearings with axle lubricant. the correct feeler gage thickness. This is the
B. Support the case to keep it from falling into the zero setting without preload.
axle housing. 6. Remove the strap, J 22779, service spacer, service
shim, feeler gage, and differential case from the
2. Insert J 22779 between the axle housing and the axle housing.
left bearing cup (figure 21).
Figure 22—Measuring Side Bearing Shim

Requirements
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.
l& l Tighten
A. The nut until the pinion end play is just taken

up. Rotate the pinion while tightening the nut to
seat the bearings. Once there is no end play in
the pinion, the preload torque should be
checked.
B. Remove J 8614-01. Using an inch-pound torque
wrench, check the pinion preload by rotating the
pinion with the wrench (figure 26). Preload
should be at or below 2.7 to 3.6 N-m (24 to 32
lbs. in.) on new bearings, or 1.0 to 1.4 N-m (8
to 12 lbs. in.) for used bearings.
C. If the preload torque is below the specified val
ues, continue torquing the nut in small incre
ments. Check the preload after each tightening.
Each tightening increases the bearing preload
by several pounds. If the bearing preload is
exceeded, the pinion will have to be removed,
and a new collapsible spacer installed.
D. Once the specified preload has been obtained,
rotate the pinion several times to ensure the
6. Check and record the backlash at three or four
bearings have seated. Recheck the preload and
points around the ring gear.
adjust if necessary.
8. Differential case. Refer to “Backlash Adjustment.” • The pinion must be held stationary when check
ing backlash.
BACKLASH ADJUSTMENT
• The backlash should be the same at each point
1. Install the differential case, bearing cups, spacers,
within 0.05 mm (0.002 inch). If the backlash
and shims as determined from the “Side Bearing
varies more than 0.05 mm (0.002 inch), check
Preload Adjustment.”
for burrs, a distorted case flange, or uneven
2. Rotate the case several times to seat the bearings.
bolting conditions.
3. Install a dial indicator to the case using a magnetic
base. 7. Backlash at the minimum lash point measured
4. Place the indicator stem at the heel end of a tooth should be 0.13 to 0.23 mm (0.005 to 0.009 inch)
(figure 27). for all new gear sets.
• Set the dial indicator so the stem is in line with 8. If the backlash is not within specifications, move
the gear rotation and perpendicular to the tooth the ring gear in or out from the pinion by increasing
angle. the thickness of one shim, and decreasing the
5. Install the differential bearing caps and bolts. thickness of the other shim the same amount. This
will maintain the correct axle side bearing preload.
Si Tighten
• Moving 0.05 mm (0.002 inch) worth of shim
Bolts to 75 N-m (55 lbs. ft.). from one side of the differential to the other will
change the backlash adjustment by 0.03 mm
(0.001 inch).
9. When the backlash is correctly adjusted, remove
the bearing caps and shim packs.
10. Select a shim 0.10-mm (0.004-inch) thicker than
the one removed from the left side. Insert this shim
between the spacer and left bearing race (figure
28).
11. Install the left bearing cap and bolts.
• Do not tighten.
12. Select a shim 0.10-mm (0.004-inch) thicker than
the one removed from the right side. Insert the
shim between the spacer and right bearing race,
and drive the shim into place.
13. Install the right side bearing cap, and bolts.
£ Tighten
• Bolts to 75 N-m (55 lbs. ft.).

Figure 26—Checking Pinion Preload 14. Recheck the backlash and correct as necessary.
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 23765 Axle Shaft Bearing Installer
J 23771 Axle Shaft Seal Installer
J 23911 Pinion Oil Seal Installer
-►4- Install or Connect
Bearing with J 23765 and J 8092 until the tool bot

toms against the housing shoulder (figure 31).
• Lubricate the bearing with axle lubricant.
Oil seal using J 23771 until it is flush with the axle
tube (figure 32).
• Lubricate the seal lips with axle lubricant.
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
DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE

(CONVEX) (CONCAVE) (CONVEX) (CONCAVE)
CORRECTION: CORRECTION:
INCREASE THE PINION SHIM THICKNESS. NONE.
SERVICE HINTS: SERVICE HINTS:

HOW TO CHECK PATTERNS: PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE
• BRUSH GEAR MARKING COMPOUND BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE
ON THE RING GEAR TEETH. CHECK THESE BEARING PRELOAD SETTINGS:
• ROTATE THE PINION SIX TIMES CLOCKWISE • TOTAL ASSEMBLY
AND SIX TIMES COUNTERCLOCKWISE. • DIFFERERTIAL CASE
• OBSERVE THE TOOTH CONTACT PATTERN • PINION
AND MAKE ANY NECESSARY CORRECTIONS. IF THESE SETTINGS ARE GOOD, LOOK FOR
DAMAGED OR INCORRECTLY ASSEMBLED PARTS.
CONDITION:
• BACKLASH CORRECT.
• PINION DEPTH INCORRECT-PINION GEAR
IS TOO CLOSE TO RING GEAR.
TOE
DRIVE SIDE COAST SIDE

(CONVEX) (CONCAVE)
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 30—Gear Tooth Pattern

Figure 31—Installing the Axle Bearing Figure 33— "C" Lock and Axle Shaft Seated in the
Side Gear
4. The "C" locks on the axle shaft.

• Pull the axle shaft outward so the "C" lock
seats in the counterbore of the axle side gear
(figure 33).
5. Pinion shaft through the case and the differential
gears.
• Align the hole in the pinion shaft with the lock
bolt hole.
6. Pinion shaft lock bolt.
& Tighten
• Lock bolt to 34 N-m (25 lbs. ft.).

7. Cover gasket and cover.
Tighten
• Cover bolts to 27 N-m (20 lbs. ft.).

8. Lubricant to the axle.
Figure 32—Installing the Axle Seal • Lubricant to a level within 9.5 mm (3/8 inch) of
the filler plug hole.
3. Axle shafts into the axle housing.
• Be careful not to damage the oil seal. & Tighten
• The splines at the end of the axle shaft must
engage with the splines of the axle side gear. 9. Fill plug to 35 N-m (26 lbs. ft.).
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
Spacer and Shim Sizes Size

Differential Side Bearing Spacer.... 0.170-inch
Differential Side Bearing Shim Kits. 0.040- 0.044- nch

0.046- 0.050- nch
0.052- 0.056- nch
0.058- 0.063- nch
0.064- 0.070- nch
0.072- 0.078- nch
0.080- 0.086- nch
0.088- 0.094- nch
0.096- 0 . 100- nch
Pinion Bearing Shim Kits. 0.025-0.029-inch

0.030-0.034-inch
0.035-0.039-inch
0.040-0.045-inch
LUBR IC ATIO N
Type 80W-90 GL-5
Liters Pints
Capacity. 1.85 4.0
T2508
SPECIAL TOOLS
1. J 7817 8. 22813-01
J 7818 9. 23911
3. J 8107-2 10. 25299
4. J 8 6 1 4 -0 1
11 . 25320
12. 8092
5. J 22779
13. 8001
6. J 22888
J 5590 14. 23771

7.
1. Front Pinion Bearing Cup Installer f

2. Rear Pinion Bearing Cup Installer 15.
3. Differential Side Bearing Remover Plug
4. Pinion Flange Holder and Remover 2619-01
5. Side Bearing Backlash Gage
6. Side Bearing Remover
7. Rear Pinion Bearing Cone Installer
8. Axle Bearing Puller
9. Pinion Oil Seal Installer
10. Differential Side Bearing Installer
16. 23765
11. Rear Pinion Bearing Remover
12. Driver Handle
13. Dial Indicator
14. Axle Seal Installer 17. 297 1 0
15. Slide Hammer
16. Axle Bearing Installer
17. Differential Side Bearing
Installer
3704S2402
8 1/2 AND 8 5/8-INCH RING GEAR 4B2-1
SECTION 4B2
8 1/2 AND 8 5/8-INCH RING GEAR

Section 9J under ’’ON-VEHICLE SERVICE” and the SIR Component and Wiring Location view in Section
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................. 4B2- 1
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 Installation..................................................................................................................................................4B2- 8
Differential Case Assembly............................................................................................................................ 4B2- 8
Side Bearing Pre-Load Adjustment............................................................................................................. . 4B2- 9
Backlash Adjustment........................................................................................................................................ 4B2-10
Gear Tooth Nomenclature................................................................................................................................ 4b2-11
Adjustments Affecting Tooth Contact.............................................................................................................. 4B2-13
Final Assembly...................................................................................................................................................4B2-13
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
when setting up the shim packs for locating and
preloading the differential case.
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
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).
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.
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.
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
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.
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
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.
The sealing surface of the pinion flange for nicks,

burrs, or rough tool marks that would cause dam
age to the seal’s inside diameter and result in an
oil leak.
Replace all worn or broken parts.
J 8092
— Ring and pinion gears are matched sets and
both must be replaced any time a replacement
J 7817
of either is necessary.
Important
• A new pinion flange must be replaced when

ring gear and pinion gear are replaced to main
tain proper system balance.
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
• Shims for cracks and chips. Damaged shims

should be replaced with an equal size service
shim.

Install or Connect (Figures 1, 10, 11, 12, 13
and 14)
Tools Required:
J 8608 Rear Pinion Bearing Cup Installer
J 8611-01 Front Pinion Bearing Cup Installer
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).
7. Tighten the stud nut until a torque of 1.6 to 2.2 N-m

(15 to 25 lbs. in.) is obtained to keep the gage
plate in rotation.
8. Assemble J 21777-45, J 21777-1, and J 8001 to
the differential bearing bore as shown in (figure
13).
• The bearing bores must be clean and burr free.
9. Install the side bearing caps.
Tighten
• Bolts to 74 N-m (55 lbs. ft.)

10. Rotate the gage plate until the proper gaging area
is parallel with the discs.
11. Position the gage shaft assembly in the carrier so
the dial indicator rod is centered on the gage area
of the gauge block.
12. Set the dial indicator at zero. Push the indicator
approximately 3/4 of a turn to the right. Tighten the
dial indicator in this position.
the dial indicator reads the greatest deflection. This
is when the indicator needle is centered between
movement to the left and to the right.
14. At the point of greatest deflection, set the dial indi
cator to zero. Repeat the rocking action of the
15. Rotate the gage shaft until the dial indicator rod
does not touch the gage block. 16 Record the actu
al number on the dial indicator and not the number
which represents how far the needle travels. This is
the nominal pinion setting. EXAMPLE: The indica
tor needle moved counter clockwise 1.70 mm
(0.067 inch) to a dial reading of 0.84 mm (0.033
inch) (figure 14). Record the dial reading of 0.84
mm (0.033 inch), NOT 1.70 mm (0.067 inch).
Figure 14— Checking Pinion Depth 16. Check the pinion face for a pinion adjustment
mark. This mark indicates the best running position
PINION DEPTH ADJUSTMENT
for the pinion from the nominal setting.
Tools Required:
J 8001 Dial Indicator Gage Set • If the pinion has no plus or minus marked on it,
J 21777-1 Arbor use the nominal pinion setting to select a shim.
J 21777-29 Gage Plate
J 21777-35 Rear Pilot Washer 17. Remove bearing caps (10) and depth gaging tools.
J 21777-42 Front Pilot Washer 18. Install the correct pinion shim (6) to the pinion
J 21777-43 Stud Assembly— Bolt according to this procedure.
J 21777-45 Side Bearing Disc
1. Clean all the gage parts.
NOTICE: Proper pinion depth setting is a
2. Lubricate the front and rear pinion bearings with
two-step procedure.
axle lubricant.
3. Place the bearings into the pinion bearing cups.
1. Setup dimension arrived at with the
indicator to be considered a starting
4. Install J 21777-35, J 21777-42, J 21777-29, and
point.
5. Hold the stud stationary at the flats of the stud.
2. Gear tooth pattern check is necessary
to "fine tune" the pinion depth and may
Tighten indicate additional shim changes to the
• Stud nut to 2.2 N-m (20 lbs. in.). performed to ensure proper axle perfor
6. Rotate the gage plate and bearings several com mance and prevent system damage.
plete revolutions to seat the bearings.
6. Pinion flange (37) to the pinion by tapping it with a

PINION INSTALLATION soft faced hammer until a few threads show
Install or Connect (Figures 1, 15, and 16) through the pinion flange.
7. Pinion washer (36) and a new nut (35) while hold
ing the pinion flange with J 8614-01 (figure 16).
Tools Required:
J 8609-01 Rear Pinion Bearing Cone Installer Adjust
J 8614-01 Pinion Flange Remover A. The nut until the pinion end play is just taken
J 5590 Rear Pinion Bearing Cone Installer up. Rotate the pinion while tightening the nut to
• The bearing cups should have been installed in seat the bearings. Once there is no end play in
“Pinion Depth Adjustment.” the pinion, the preload torque should be
1. The pinion inner bearing (5) using J 8609-01. rechecked.
• Press the bearing onto the pinion until the bear B. Remove J 8614-01. Using an inch-pound torque
ing cone seats on the pinion shims. wrench, check the pinion preload by rotating the
2. A new collapsible spacer (4). pinion with the wrench. Preload should be at or
• Lubricate the pinion bearings with axle lubricant. below 2.3 to 2.8 N-m (20 to 25 lbs. in.) on new
3. Pinion (7) to the axle housing. bearings, or 1.1 to 1.7 N-m (10 to 15 lbs in.) for
4. Outer pinion bearing (39) onto the pinion using used bearings (figure 17).
J 5590. C. If the preload torque is below the preloads giv
• Hold the pinion forward from inside the case en above, continue torquing the nut in small
while driving the bearing onto the pinion. increments. Check the preload after each tight
5. Pinion oil seal (38) using J 22388 (figure 15). ening. Each tightening increases the bearing
preload. If the bearing preload is exceeded, the
pinion will have to be removed and a new col
lapsible spacer installed.
D. Once the preload has been obtained, rotate the
pinion several times to ensure the bearings
J 22388 have seated. Recheck the preload, and adjust if
necessary.
8. Differential case. Refer to “Backlash Adjustment.”
Install or Connect (Figure 1)
Tools Required:
Plug
• 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
2. Side gears (22) to the differential case (24).

• Reinstall the side gears on the same side as
removed.
3. Pinion gears (21) to the differential without the
thrust washers (20).
• Place one pinion gear onto the side gears so
the holes in the pinion gears are 180 degrees
apart.
• Rotate the pinion gears into place, and verify
that the pinion gears line up with the pinion
shaft holes.
4. Pinion thrust washers (20).
• Rotate the pinion gears toward the differential
opening enough to slide in the pinion thrust
washers.
• Make sure the mating surfaces of the differen
tial case and ring gear are clean and burr free.
5. Ring gear (7) to the differential case (24).
A. Thread two left-hand threaded studs into the
ring gear on opposite sides (figure 18). Figure 18—Aligning the Ring Gear Studs
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 8107-4 to protect the dif
ferential from the press ram (figure 19).
6. Ring gear bolts (23).
• Tighten the ring gear bolts alternately in stages
gradually pulling the ring gear onto the differen
tial case.
St Tighten
• The ring gear bolts in sequence to 120 N-m (90

Ibs.ft.).
7. Differential side bearings (8) using J 22761,
J 8107-4,and J 8092 (figure 20).
A. Place J 8107-4 into the differential on the side
opposite of bearing installation to protect the
differential case.
B. Drive the bearing onto the case using J 22761
and J 8092.
8. Differential case (24) to the axle housing. Refer to
“Side Bearing Preload Adjustment.”
SIDE BEARING PRE-LOAD ADJUSTMENT
• The differential side bearing preload is adjusted by
changing the thickness of the left and right shims
equally. This will not change the original backlash.
• Production shims are cast iron and are not to be
reused.
• Service spacer thickness is nominal at 4.32 mm
(0.170 inch).
• Service shims are available from 1.02 mm to 2.54
mm (0.040 to 0.100 inch) in increments of 0.101
J 22761
mm (0.004 inch).
• Make sure the side bearing surfaces are clean and
free of burrs.
Tool Required:
J 22779 Side Bearing Backlash Gage
1. Place the differential case and the bearing cups
into the axle housing.
A. Lubricate the axle bearings with axle lubricant. J 8107-4
B. Support the case to keep it from falling into the
axle housing.
2. Install the strap from J 22779 on the left bearing Figure 20— Installing the Side Bearing
with the cap bolts. Tighten the bolts snugly.
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
The bolts to 80 N-m (60 lbs. ft.).
Figure 22—Measuring Side Bearing Shim

Requirements Figure 23—Measuring the Gage Plate Thickness
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.
GEAR TOOTH NOMENCLATURE

The side of the ring gear tooth which curves outward,
or is convex, is referred to as the “drive” side (4). The
concave side is the “coast” side (3). The end of the
tooth nearest the center of ring gear is referred to as
Figure 24—Installing the Final Preload Shim the “toe” end (2). The end of the tooth farthest away
TEST
torque of 54-68 N-m (40-50 lbs. ft.) is required
to turn the pinion.
6. Check and record the backlash at three or four compare with figures 27.
• The pinion must be held stationary when check
ing backlash.
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.
• PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT
TOE
HEEL A HEEL

(CONVEX) (CONCAVE)

• APPLY BRAKES SO THAT THE PINION CAN • TOTAL ASSEMBLY
BE ROTATED WITH 50 LB. FT. EFFORT. • DIFFERERTIAL CASE
• ROTATE THE PINION SIX TIMES CLOCKWISE • PINION
AND SIX TIMES COUNTERCLOCKWISE. IF THESE SETTINGS ARE GOOD, LOOK FOR
• OBSERVE THE TOOTH CONTACT PATTERN DAMAGED OR INCORRECTLY ASSEMBLED PARTS.
AND MAKE ANY NECESSARY CORRECTIONS.
CONDITION:
TOE

(CONVEX) (CONCAVE)
CORRECTION:
SERVICE HINTS:
• BETWEEN HTE INNER PINION BEARING CUP
3704r4220

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.
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.
with decreasing the right shim thickness), backlash will
decrease.
FINAL ASSEMBLY
Tools Required:
J 23771 Axle Shaft Seal Installer
Install or Connect (Figures 1, 28 through 30)
1. Bearing (27) with J 23765 and J 8092 until the tool

bottoms against the housing shoulder (figure 28).
2. Oil seal using J 23771 until the oil seal is flush with
the axle tube (figure 29).
• Lubricate the seal lips with gear lubricant.
3. Axle shafts (33) into the axle housing (1).
• Be careful not to damage the oil seal.
engage with the splines of the axle side gear.
4. "C" locks (34) on the axle shaft (33).
• Pull the axle shaft (33) outward so the "C" lock
(34) seats in the counterbore of the axle side
gear (figure 30).
5. Pinion shaft (17) through the case (24) and differ
ential gears (22).
• Align the hole in the pinion shaft with the lock
bolt hole.
6. Pinion shaft lock bolt (15).
Q Tighten
• Lock bolt (15) to 34 N-m (25 lbs. ft.).

7. Cover gasket (11) and cover (12).
Tighten
• Cover bolts (14) to 27 N-m (20 lbs. ft.).

8. Lubricant into the axle.
• Lubricant to a level within 9.5 mm (3/8 inch) of
Tighten
9. Fill plug (3) to 35 N-m (26 lbs. ft.). Side Gear

SPECIFICATIONS
Axle Cover Bolts... 27 20
Bearing Cap Bolts. 80 60
Filler Plug.............. 35 26
Ring Gear Bolts.... 120 90
SPACER AND SHIM SPECIFICATIONS
Differential Side Bearing Spacer... 0.170-inch
Differential Side Bearing Shim Kits 0.040- 0.044- nch

0.046- 0.050- nch
0.052- 0.056- nch
0.058- 0.063- nch
0.064- 0.070- nch
0.072- 0.078- nch
0.080- 0.086- nch
0.088- 0.094- nch
0.096- 0 . 100- nch
Pinion Bearing Shim Kits. 0.020-0.024-inch

0.025-0.029-inch
0.030-0.034-inch
0.035-0.039-inch
LUBRICATION
Lubricant 80W-90 GL-5
T2509
SPECIAL TOOLS
1. J 8611-01 8. J 8608
2. fO i i | J8612-B 9. J 22888
3. J 8092 10. J 22399
J 8001 11 J 22761
J 8609-01 12. J 22779
J 8614-01 13. J 5590
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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SECTION 4B3

The correct torque value must be used when installing fasteners that require it If the above conditions
CONTENTS
SUBJECT PAGE
General Description..................................................................................................................................................4B3- 1
Cleaning...................................................................................................................................................................4B3- 5
Inspection................................................................................................................................................................4B3- 5
Axle Housing......................................................................................................................................................4B3- 5
Differential........................................................................................................................................................... 4B3- 5
Bearings.............................................................................................................................................................. 4B3- 5
Shims....................................................................................................................................................................4B3- 6
Pinion Depth Adjustment.................................................................................................................................4B3- 6
Pinion Installation............................................................................................................................................. 4B3- 7
Side Bearing Preload Adjustment.................................................................................................................4B3- 9
Backlash Adjustment........................................................................................................................................ 4B3-10
Adjustments Affecting Tooth Contact.......................................................................................................... 4B3-11
Final Assembly...................................................................................................................................................4B3-11
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.
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
plug.
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
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.
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.
16 1? 19 20
1. DRUM, REAR BRAKE

2. BOLT, WHEEL
3. SHAFT, AXLE
4. SEAL, REAR AXLE SHF (OIL)
5. BEARING, REAR WHEEL 16. LOCK, DIFF BRG ADJ NUT 27. CASE. DIFFERENTIAL
6. NUT, PINION FLANGE 17. NUT, DIFF BRG ADJ 28. SHAFT, DIFF PINION
7. WASHER, PINION FLANGE 18. SCREW, HEX SERRATED WASHER 29. BOLT, DIFF LOCK
8. FLANGE ASM, PINION 19. CAP, DIFF BEARING 30. WASHER, DIFF PINION
9. SEAL ASM, PINION 20. BOLT, HEX 31. GEAR, DIFF PINION
10. BEARING, FRONT PINION 21. SHIM, DIFF BEARING ADJ 32. WASHER, DIFF SIDE GEAR
11. SPACER, PINION BEARING 22. BEARING, DIFF 33. GEAR, DIFF SIDE
12. HOUSING, AXLE 23. CUP, BRK CROSSOVER PIPE 34. PLATE, BRAKE BACKING
13. BEARING, PINION INNER 24. BOLT, HEX SERRATED COVER 35. WASHER, LOCK
14. SHIM, PINION INNER 25. COVER, DIFF CARRIER 36. BOLT, HEX
15. GEAR SET, RING AND PINION 26. BOLT, HYPOID DRIVE GEAR 37. LOCK, R/AXLE SHF
3704r5078

J 8614-3
Figure 7—Removing the Pinion Flange

Figure 8— Removing the Drive Pinion
CLEANING PINION AND RING GEAR

Do not steam-clean drive parts that have ground and • Ring and pinion gears are matched sets and both
polished surfaces such as gears, bearings, and shafts. are replaced any time a replacement of either is
All parts should be disassembled before cleaning. necessary. A new pinion flange must be replaced
These parts should be cleaned in a suitable solvent. when both ring and pinion gear are replaced to
Parts should be thoroughly dried immediately after maintain proper system balance.
dried with compressed air. Do not allow the bearings to L* Inspect
spin while drying them with compressed air.
Pinion and ring gear teeth for cracking, chipping,
INSPECTION scoring, or excessive wear.
It is critical to carefully and thoroughly inspect all Pinion splines for wear.
drive unit parts before reassembly. Pinion flange splines for wear.
Thorough inspection of the drive parts for wear or The fit of the pinion gear splines on the pinion
stress and subsequent replacement of worn parts will flange.
eliminate costly drive component repair after reassem The sealing surface of the pinion flange for nicks,
bly. burrs, or rough tool marks that could cause dam
age to the seal’s inside diameter and result in an
AXLE HOUSING oil leak.
All worn or broken parts and replace if necessary.
lv Inspect
BEARINGS
• The carrier bore for nicks or burrs that can prevent
the outer diameter of the pinion seal from sealing.
Remove any that are found.
13 Inspect
• 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.
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.
SHIMS PINION DEPTH ADJUSTMENT (Figures 12, 13, and

14)
L* Inspect
Tools Required:
J 8001 Dial Indicator Gage Set
Shims for cracks and chips. Damaged shims
J 21777-1 Arbor
J 21777-8 Rear Pilot Washer
shim.
J 21777-42 Front Pilot Washer
J 21777-43 Stud Assembly— Bolt
ASSEMBLY OF THE REAR AXLE J 21777-85 Gage Plate
J 21777-86 Side Bearing Disc
Install or Connect (Figures 1, 10, and 11)
1. Clean all gage parts.
Tools Required: 2. Lubricate the front and rear pinion bearings with
J 7817 Front Pinion Bearing Cup Installer axle lubricant.
J 22306 Rear Pinion Bearing Cup Installer 3. Place the bearings (10 and 13) into the pinion
J 8092 Driver Handle bearing cups.
4. Install J 21777-8, J 21777-42, J 21777-85, and
1. Front pinion bearing cup (10) using J 7817 and
J 8092.
5. Hold the stud stationary at the flats of the stud.
2. Rear pinion bearing cup (13) using J 22306 and
J 8092.
Figure 12—Gage Plate Tools

Figure 10—Installing the Front Pinion Bearing Cup
F4698
Figure 11—Installing the Rear Pinion Bearing Cup Figure 13— Pinion Depth Tools
17. All drive pinions are manufactured to a nominal

depth. There are no markings on the drive pinion
relating to depth. The dial indicator reading is used
for shim selection.
18. Remove bearing caps (19) and depth gaging tools.
19. Install the correct pinion shim (14) to the pinion
according to this procedure.

two-step procedure.
point.
to ”fine tune” the pinion depth and may
performed to ensure proper axle perfor
Figure 14— Checking Pinion Depth PINION INSTALLATION (Figures 1, 15 through 18)
$ Tighten ■*4 Install or Connect
• Stud nut to 2.2 N-m (20 lbs. in.). Tools Required:

6. Rotate the gage plate and bearings several com J 22388 Pinion Oil Seal Installer
plete revolutions to seat the bearings. J 22804-1 Pinion Oil Seal Spacer
7. Tighten the stud nut until a torque of 1.6 to 2.2 N-m J 5590 Rear Pinion Bearing Cone Installer
(15 to 25 lbs. in.) is obtained to keep the gage • The bearing cups should have been installed in
plate in rotation. “Pinion Depth Adjustment.”
8. Assemble J 21777-86, J 21777-1, and J 8001 to 1. The pinion inner bearing (13) to the pinion.
the differential bearing bore (figure 13).
• Press the bearing onto the pinion until the bear
• The bearing bores must be clean and burr free. ing cone seats on the pinion shim(s) (figure 15).
9. Install the side bearing caps.
2. A new collapsible spacer (11).
Tighten • Lubricate the pinion bearings with axle lubri
$ cant.
• Bolts to 74 N m (55 lbs. ft.). 3. Pinion (15) to the axle housing.
10. Rotate the gage plate until the proper gaging area 4. Outer pinion bearing (10) onto the pinion using
is parallel with the disks. J 5590.
11. Position the gage shaft assembly in the carrier so • Hold the pinion forward from inside the case
the dial indicator rod is centered on the gaging while driving the bearing onto the pinion.
area of the gage block.
12. Set the dial indicator at zero. Push the indicator
approximately 3/4 of a turn to the right. Tighten the
dial indicator in this position (figure 14).
the dial indicator reads the greatest deflection
(when the indicator needle is centered between
movement to the left and to the right).
14. At the point of greatest deflection, set the dial indi
cator to zero. Repeat the rocking action of the
15. Rotate the gage shaft until the dial indicator rod
does not touch the gage block.
16. Record the actual number on the dial indicator and
not the number which represents how far the nee
dle travels. This is the nominal pinion setting.
EXAMPLE: If the indicator needle moved coun-
ter-clockwise 1.70 mm (0.067 inch) to a dial read
ing of 0.84 mm (0.033 inch) as shown in figure 14,
record the dial reading of 0.84 mm (0.033 inch),
not 1.70 mm (0.067 inch).
5. Pinion oil seal (9) using J 22388 (figure 16).

6. The pinion flange (8) to the pinion by tapping it with
a soft-faced hammer until a few threads show
through the pinion flange.
7. The pinion washer (7) and nut (6) while holding the
pinion flange with J 8614-01 (figure 17).
Tighten
• The nut until the pinion end play is just taken

up. Rotate the pinion while tightening the nut to
rechecked.
• Remove J 8614-01. Using an inch-pound torque
pinion with the wrench. Preload should be at or
below 2.3 to 2.8 N m (20 to 25 lbs. in.) on new
bearings, or 1.1 to 1.7 N-m (10 to 15 lbs. in.) for
used bearings (figure 18).
• If the preload torque is below the preload val
ues given above, continue tightening the nut in
small increments. Check the preload after each
tightening. Each tightening increases the bear
ing preload by several pounds. If the bearing
preload is exceeded, the pinion will have to be
removed and a new collapsible spacer installed.
• Once the preload has been obtained, rotate the
pinion several times to make sure the bearings
are seated. Recheck the preload and adjust if
necessary.
8. Differential case. Refer to “Backlash Adjustment.”
Install or Connect (Figure 1, 19 through 22)
Tools Required:
J 8107-3 Differential Side Bearing Removal Plug
1. Lubricate all parts with axle lubricant.
2. Side gear thrust washers (32) to the side gears
Figure 17—Installing the Pinion Flange (33). “
Figure 18—Checking Pinion Bearing Preload

Figure 19—Aligning the Ring Gear Studs
3. Side gears (33) to the differential case (27).

• Install the side gears on the same side as when
removed.
4. Pinion gears (31) to the differential without the pin
ion thrust washers (30).
A. Install the pinion gears onto the side gears so
the holes in the pinion gears are 180 degrees
apart.
B. Rotate the pinion gears into place, and verify
the pinion gears line up with the pinion shaft
holes.
5. Pinion thrust washers (30).
opening enough to slide in the pinion thrust
washers.
• Make sure the mating surfaces of the differen
tial case and ring gear are clean and burr free.
6. Ring gear (15) to the differential case (27).
A. Thread two left-hand threaded bolts into the ring
gear on opposite sides.
B. Place the ring gear onto the case, and align the
holes in the case with the bolts (figure 19).
start the bolts using J 8107-3 to protect the
differential from the press ram (figure 20).
• Tighten the ring gear bolts alternately, and in
stages gradually pulling the ring gear onto the
J 8092 differential case.
J 29710
£ Tighten
• Bolts (26) to 145 N.m (105 lbs. ft.).

8. Differential side bearings (22) using J 29710,
J 8107-3, and J 8092 (figure 21).
• Place J 8107-3 into the differential on the side
opposite the bearing installation to protect the
J 8107-3 differential case.
F4732 • Drive the bearing onto the case using J 29710
and J 8092.
Figure 21—Installing the Side Bearing
9. Differential case (27) to the axle housing. Refer to
“Side Bearing Preload Adjustment.”
SIDE BEARING PRELOAD ADJUSTMENT
a nut in the differential bearing bore. The bore and
bearing cap provide the mating threads for the nut.
• The differential must be initially preloaded in order
to determine the backlash of the gear set. After the
backlash has been set, the final bearing preload is
set.
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.
4. Backlash at the minimum lash point measured

should be between 0.125-0.200 mm (0.005-0.008
inch).
A. If the reading is too high, increase the shim
pack between the differential flange side of the
case and the axle housing (opposite the adjust
ing nut side).
B. If the reading is too low, decrease the shim
pack between the differential flange side of the
case and the axle housing (opposite the adjust
ing nut side).
5. Adjust the side bearing preload. Refer to “Side
Bearing Preload Adjustment.”
GEAR TOOTH
PATTERN CHECK
4. Adjusting nut (17). ously outlined. It is a method to verify the correct
A. Tighten the adjusting nut using J 24429.
B. Turn the pinion to seat the bearings.
C. Back off the adjusting nut.
5. Bearing caps (19) and bolts (20) in their original pinion for low noise level and long life can be ensured.
positions.
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
Tighten the “toe” end (2). The end of the tooth farthest away
• Bolts (20) to 80 N-m (60 lbs. ft.). tooth is smaller than the heel end (figure 24).
6. Adjusting nut lock (16) and lock bolt (18). TEST

• Measure the ring gear to pinion backlash. Refer 1. Wipe oil out of axle housing and carefully clean
to “Backlash Adjustment.” each tooth of the ring gear.
Tighten ring gear teeth using a medium stiff brush.
Bolt (18) to 30 N-m (22 lbs. ft.) after setting the

backlash.
BACKLASH ADJUSTMENT
1. Install a dial indicator on the case using a magnetic
base.
• Set the dial indicator so the stem is in line with
the gear rotation and perpendicular to the tooth
angle.
points around the ring gear (figure 23).
ing backlash.
case and ring gear.
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
bly closer to or farther from the drive pinion. The adjust
ing shims are also used to set side bearing preload.
compare with figure 25. with decreasing the left shim thickness), backlash will
increase.
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
ments should be within specifications before proceeding
with backlash and drive pinion adjustments. J 23771 Axle Shaft Seal Installer
TOE TOE
HEEL / \ HEEL HEEL HEEL
\ Jw
\4 L
t f S I


CONDITION:
CORRECTION:
SERVICE HINTS:
3704r5056
Figure 25 Gear Tooth Pattern

+4- Install or Connect (Figures 1, 2, 26, and 27)
1. Bearing (5) with J 23765 and J 8092 until the tool

bottoms against the housing shoulder (figure 26).
2. Oil seal using J 23771 until the seal is flush with
the axle tube (figure 27).
• Lubricate the seal lips with axle lubricant.
3. Axle shafts (3) into the axle housing (12).
• Be careful not to damage the oil seal.
engage with the splines of the axle side gear.
4. “C” clips (37) on the axle shaft (3).
• Pull the axle shaft (3) outward so the “C” clip
(37) seats in the counterbore of the axle side
gear.
5. Pinion shaft (28) through the case (27) and differ
ential gears (33).
• Align the hole in the pinion shaft (28) with the
lock bolt hole.
Important
• Anytime a differential pinion shaft locking screw is

removed, it is important to coat the screw threads
with Loctite 242 before reinstalling. These screws
are coated with an adhesive which helps to prevent
the screw from loosening in the case. When this
screw is removed, the adhesive is also removed.
6. New pinion shaft lock bolt (29).
Tighten
• Lock bolt (29) to 36 N-m (27 lbs. ft.).

7. A new cover gasket and cover (25).
Tighten
• Cover bolts (24) to 27 N-m (20 lbs. ft.).

8. Lubricant in the axle.
• Lubricant to a level within 9.5 mm (3/8 inch) of
9. Fill plug. Figure 27—Installing the Axle Seal
HI Tighten
Fill plug to 35 N-m (26 lbs. ft.).

SPECIFICATIONS
9 1/2-INCH RING GEAR AXLE
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

Differential Side Bearing Spacer................................................................................................ 0.170-inch
0.040-0.044-inch
Differential Side Bearing Shim Kits. 5.59 mm (0.220- nch)

5.64 mm (0.222- nch)
5.69 mm (0.224- nch)
5.74 mm (0.226- nch)
5.79 mm (0.228- nch)
5.84 mm (0.230- nch)
5.89 mm (0.232- nch)
5.94 mm (0.234- nch)
5.99 mm (0.236- nch)
6.05 mm (0.238- nch)
6.10 mm (0.240- nch)
6.15 mm (0.242- nch)
6.20 mm (0.244- nch)
6.25 mm (0.246- nch)
6.30 mm (0.248- nch)
6.35 mm (0.250- nch)
6.40 mm (0.252- nch)
6.45 mm (0.254- nch)
6.50 mm (0.256- nch)
6.55 mm (0.258- nch)
Pinion Bearing Shim Kits. 0.5080- 0.5842 mm

( 0 . 020- 0.023-inch)
0.6096- ■0.7112 mm
(0.024- 0.028-inch)
0.7366- 0.8382 mm
(0.029- 0.033-inch)
0.8636- 0.9398 mm
(0.034- 0.037-inch)
LUBRICATION
Type................................................................................................................................................ 80W-90 GL-5
Capacity.......................................................................................................................................... 2.7 Liters (5.5 Pints)
T2510
SPECIAL TOOLS
1. J 8 1 0 7 -3 J 22888
2. J 23765 J 24433
3. J 24429 J 22388
4. J 22912-01 13. J 8614-01
5. J 5590 14. i$ = 4 )= d J 22813-01
6. J 7817 15. J 2619-01
7. J8092
8. J 8001 - M 16. J 23771
9. J 29710 17. J 23911
1. Differential Side Bearing Plug 14. Axle Bearing Remover

2. Axle Shaft Bearing Installer 15. Slide Hammer
3. Side Bearing Adjustment Spanner 16. Axle Shaft Seal Installer
4. Rear Pinion Bearing Cone Remover 17. Pinion Oil Seal Installer
6. Front Pinion Bearing Cup Installer Refer to Figures 12 and 13 for these tools:
7. Driver Handle
8. Dial Indicator J - 21777-1 Arbor
9. Differential Side Bearing Installer J - 2 1 7 7 7 -8 Rear Pilot Washer
10. Side Bearing Remover J - 2 1 7 7 7 -4 2 Front Pilot Washer
11. Rear Pinion Bearing Cone Installer J - 2 1 7 7 7 -4 3 Stud Assembly - Bolt
12. Pinion Oil Seal Installer J - 2 1 7 7 7 -8 5 Gauge Plate
13. Pinion Flange Remover J - 2 1 7 7 7 -8 6 Side Bearing Disc
8 J0 0 T moma
m m m
. '.-.atfiieO■t
•.
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.
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).
Pinion Pilot Bearing

Axle Vent Tube
Axle Housing
Differential Side Bearing
Bearing Adjusting Nut
Bearing Cap
Adjusting Nut Lock
Bolt
Gasket
Cover
Bolt
Brake Line Clip
Washer
Bolt
Side Gear
Side Gear Thrust Washer
Pinion Gear Thrust Washer
Pinion Gear Set

Pinion Cross Shaft
Differential Case
Washer
Ring Gear Bolt
Brake Backing Plate
Bolt
Axle Shaft Seal
Bearing
Retaining Ring
Bearing
6. Pinion Front Bearing Lock Nut
7. Bolt Key
8. Washer Retaining Ring
9. Brake Line Clip 46. Bolt
1. Pinion Nut 10. Pinion Cage 47. Axle Shaft
2. Washer 11. Shim 48. Gasket
3. Pinion Flange 12. Collapsable Spacer 49. Wheel Stud
4. Slinger 13. Pinion Rear Bearing 50. Wheel Hub
5. Pinion Oil Seal 14. Pinion and Ring Gear Set 51. Brake Drum
F5900
Figure 1— Rear Axle Components

Figure 4— Removing the Drive Pinion Nut Figure 7—Removing the Pinion Inner Bearing
AXLE HOUSING
1? Inspect
• The axle housing bore for nicks or burrs that can

prevent the outer diameter of the pinion seal from
any burrs.
• The housing for cracks. Replace the housing if any
cracks are found.
chips, dirt, or rust. Refer to “Cleaning.”
DIFFERENTIAL
e Inspect
• Pinion shaft for unusual wear.

scoring, and spalling.
• The fit of the side gears in the differential case.
• Differential case for cracks and scoring.
• All parts for wear and replace if necessary.
PINION AND RING GEAR

• Ring and pinion gears are matched sets and both
are replaced any time a replacement of either is
necessary. A new pinion flange must be replaced
when both ring gear and pinion gear are replaced
to maintain proper system balance.
Lv Inspect
• Pinion and ring gear teeth for cracking, chipping,

scoring, or excessive wear.
• Pinion splines for wear.
• Pinion flange splines for wear.
Figure 9— Installing the Inner Pinion Bearing • The fit of the pinion gear splines on the pinion
flange.
CLEANING • The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause dam
Do not steam clean drive parts that have ground and age to the seal’s inside diameter and result in an
polished surfaces such as gears, bearings, and shafts. oil leak.
All parts should be disassembled before cleaning. • All worn or broken parts and replace if necessary.
These parts should be cleaned in a suitable solvent.
Parts should be thoroughly dried immediately after BEARINGS
dried with compressed air. Do not allow bearings to spin Inspect
while drying them with compressed air.
Bearings for smooth rotation after oiling them.
INSPECTION Bearing rollers for wear.
Bearing cups for wear, cracks, brinelling, and scor
It is critical to carefully and thoroughly inspect all ing.
Thorough inspection of drive parts for wear or stress Important
and subsequent replacement of worn parts will elimi
nate costly drive component repair after reassembly. When replacing worn or cracked bearings and
Ring gear and pinion gear for wear. If worn,
replace them as a set.
; Important
• 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.
SHIMS
L* Inspect

shim.

PINION ASSEMBLY
“►+ Install or Connect (Figures 1 and 9 through
— ' 13)
Tools Required:
Figure 11—Checking Pinion Preload
J 24433 Rear Pinion Bearing Cone Installer
J 8608 Outer Pinion Bearing Cup Installer
J 8614-01 Pinion Flange Holder
• Lubricate all parts with axle lubricant.
1. Pinion rear bearing (13) onto the pinion.
• Press the bearing onto the pinion using J 24433 J 8092
(figure 9).
2. Outer pinion bearing cup (6) using J 8608 and
J 8092.
3. Inner pinion bearing cup (13) using J 24432 and J 34943
J 8092.
4. A new collapsible spacer (12) to the pinion.
5. Pinion (14) into the cage (10). J 34943
6. Pinion outer bearing (6) onto the pinion.
• Press the bearing onto the pinion.
7. Pinion oil seal (5) using J 24433 and J 8092.
8. Pinion flange oil deflector (4) and pinion flange (3)
to the pinion splines.
9. Washer (2) and pinion nut (1).
A. Place the pinion cage assembly into the vise.
Figure 12—Installing the Pilot Bearing
B. Flange holder J 8614-01 to the pinion flange.
Figure 13—Installing the Pinion Cage

Figure 10— Installing the Pinion Nut
& Tighten (Figure 10) 1 Tighten
• 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
+«- Install or Connect (Figure 1, 14, and 15)
checked.
• Remove J 8614-01. Using an inch-pound torque
Tools Required:
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.”

two-step procedure.
point.
to ”fine tune” the pinion depth and may
performed to ensure proper axle perfor
PINION INSTALLATION
Tools Required:
J 34943 Pinion Pilot Bearing Installer
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).
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.
start the bolts using J 8107 to protect the differ
ential from the press ram.
$ Tighten
A. The ring gear bolts alternately in stages gradu

ally pulling the ring gear onto the differential
case.
B. The ring gear bolts in sequence to 163 N m
(120 lbs. ft.).
7. Differential side bearings (18) using J 24429 and case into solid contact with the left adjusting
J 8092 (figure 15). nut. Rotate the pinion several times to seat the
A. Place J 8107 into the differential on the side bearings.
opposite of bearing installation to protect the C. Loosen the right adjusting nut until it is free
differential case. from its bearing.
B. Drive the bearing onto the case using J 24429 D. Tighten the right adjusting nut until it just con
and J 8092. tacts the bearing. Additionally tighten the nut
8. Differential case (34) to the axle housing. Refer to two slots for used bearings, or three slots if new
“Side Bearing Preload Adjustment.” bearings are installed.
SIDE BEARING PRELOAD ADJUSTMENT Tighten

two adjusting nuts in the bearing bore. The bore • Bearing cap bolts (28) to 183 N m (135 lbs. ft.).
and the bearing cap provide the mating threads for
the bearing nut. • Measure the ring gear to pinion backlash. Refer to
• The differential must be initially preloaded in order “Backlash Adjustment.”
to determine the backlash of the gear set. After the
backlash has been set, the final bearing preload is BACKLASH ADJUSTMENT
set. 1. Install a dial indicator to the case using a magnetic
base (figure 17).
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

• Set the dial indicator so that the stem is in line
with the gear rotation and perpendicular to the
tooth angle.
ing backlash.
case and the ring gear.
4. The backlash at the minimum lash point measured
should be between 0.125-0.200 mm (0.005-0.008
inch). The maximum acceptable reading is
0.076-0.203 mm (0.003-0.008 inch).
5. If the reading is too high, remove the adjusting nut
locks, and loosen the right nut one slot. Then tight
en the left nut one slot (figure 16).
6. If the reading is too low, remove the adjusting nut
locks, and loosen the left nut one slot. Then tighten 4. Observe the pattern on the ring gear teeth and
the right nut one slot. compare with figure 19.
• The side bearing preload will not change as
long as the adjusting nut is tightened an equal ADJUSTMENTS AFFECTING
amount to the nut which was loosened.
TOOTH CONTACT
GEAR TOOTH tact pattern: backlash and pinion depth. The effects of
PATTERN CHECK bearing preloads are not readily apparent on hand load
Before final assembly of the differential, a gear tooth ed tooth contact pattern tests; however, these adjust
contact pattern check should be performed. ments should be within specifications before proceeding
A gear tooth contact pattern check is NOT a substi with backlash and drive pinion adjustments.
tute for adjusting pinion depth and backlash as previ Pinion depth is adjusted by increasing or decreasing
ously outlined. It is a method to verify the correct the distance between the pinion head and the centerline
running position of the ring gear and the drive pinion. of the ring gear. The shim is used in the axle to com
Gear sets which are not positioned properly may be pensate for manufacturing tolerances. Decreasing the
noisy, have a short life, or both. With a pattern check, distance will move the pinion closer to the centerline of
the best contact between the ring gear and the drive the ring gear. Increasing the distance will move the
pinion for low noise level and long life can be ensured. pinion farther away from the centerline of the ring gear.
adjusting shims and/or adjusting nuts. These move the
case and ring gear closer to, or farther from, the drive
pinion. The adjusting shims are also used to set side
bearing preload.
with an equal decrease in the left shim thickness),
backlash will increase.
TEST with an equal decrease in the right shim thickness),
1. Wipe oil out of axle housing and carefully clean backlash will decrease.
2. Apply gear marking compound sparingly to all FINAL ASSEMBLY
3. Use the service brake to apply a load until a -►+ Install or Connect (Figure 1)
to turn the pinion. 1. Drive axles.
A test made without loading the gears will not 2. Gasket (23) and cover (24) to the housing.
give a satisfactory pattern. Turn the companion 3. Cover bolts (25).
rotates one full revolution. Then reverse the £ Tighten
tion in the opposite direction. Excessive turning • Cover bolts (25) to 27 N-m (20 lbs. ft.).
of the ring gear is not recommended. 4. Lubricant to the axle.
TOE TOE
HEEL HEEL HEEL A HEEL


CONDITION:
CORRECTION:
SERVICE HINTS:
3704r5056

SPECIFICATIONS
10 1/2-INCH RING GEAR AXLE (CORPORATE)
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

Pinion Bearing Shims.................................................................................................................... 0.006- nch
0.007- nch
0.008- nch
0.009- nch
0.010- nch
0.011- nch
0.012- nch
0.013- nch
0.014- nch
0.015- nch
0.016- nch
0.017- nch
0.018- nch
0.019- nch
0.020- nch
0.021- nch
0.022- nch
0.023- nch
0.024- nch
LUBRICATION
Type 80W-90 GL-5
.4 Liters (7.2 Pints)
T9F>
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
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)
be used. Fasteners that are not reused, and those requiring thread locking compound, will be called out.
CONTENTS
SUBJECT PAGE
General Description................................................................................................................................................. 4B5- 1
Cleaning...................................................................................................................................................................4B5- 6
Inspection............................................................................................................................................................... 4B5- 6
Axle Housing......................................................................................................................................................4B5- 6
Differential........................................................................................................................................................... 4B5- 7
Bearings.............................................................................................................................................................. 4B5- 7
Shims....................................................................................................................................................................4B5- 7
Determining Total Shim Pack Size............................................................................................................... 4B5- 8
Pinion Installation............................................................................................................................................. 4B5-10
Assembling the Differential into the Axle Housing................................................................................. 4B5-11
Checking Backlash........................................................................................................................................... 4B5-12
Adjustments Affecting Tooth Contact............................................................................................................. 4B5-13
Final Assembly...................................................................................................................................................4B5-13
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
Figure 1—Axle Identification

1. AXLE HOUSING 19. BOLT

2. RING GEAR AND PINION SET 20. BEARING
3. INNER PINION BEARING 21. SHIM
4. SHIMS 22. DIFFERENTIAL CASE
6. PRELOAD SHIMS 23. RING GEAR BOLT
7. BEARING 24. PINION GEAR
8. SLINGER 25. SIDE GEAR
9. PINION OIL SEAL 26. PINION THRUST WASHER
10. PINION FLANGE/YOKE 27. SIDE GEAR THRUST WASHER
11. WASHER 28. PINION SHAFT
12. PINION NUT 29. ROLL PIN
14. COVER 30. SHIM
16. PLUG 31. BOLT
17. BOLT 32. GASKET
18. BEARING CAP 37. I.D. TAG
38. AXLE SHAFT
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
• Ring gear bolts are to be replaced with new

ones at time of reassembly.
• Place shop towels over the vise jaws and put
the case in the vise.
11. Ring gear (2) from the case using a soft-faced
hammer.
A. Ring gear (2) from the vise.
B. Put the case back in the vise.
case. This will damage the ring gear and
case.
12. Roll pin (29) from the case using a hammer and
Figure 3—Spreading the Differential Case punch (figure 6).
Figure 4 — Removing the Differential Figure 5— Removing the Differential Side Bearings
13. Pinion shaft (28) using a hammer and brass drift

(figure 7).
14. Pinion gears (24) and thrust washers (26).
• Rotate the side gears until the pinion gears are
in the opening of the case (figure 8).
15. Side gears (25) and thrust washers (27).
• Mark the gears and washers left and right.
16. Replace the cover (14) using two bolts (17) to keep
the pinion from falling.
I? Inspect
Drive pinion rotating torque and record (figure

9).
For looseness of the pinion assembly by mov
ing it back and forth. (Looseness indicates
excessive bearing or pinion wear).
Figure 8—Removing/Installing the Pinion Gears
17. Pinion nut (12) and washer (11) using J 8614-01 to

hold the pinion (figure 10).
18. Pinion flange (10) using J 8614-01 (figure 11).
19. Pinion (2) from the housing using a soft-faced ham
mer to tap the pinion.
CAUTION: Do not allow the pinion to fall. It

can strike legs or feet and may cause serious
injury. Also, gear teeth may have sharp
edges. When handling, use care to avoid cut
ting hands.
20. Cover (14) and pinion (2).

21. Pinion preload shims (6).
• Keep the shims together.
22. Pinion seal (9).
23. Outer bearing (7) and oil slinger (8).
Figure 10— Removing the Drive Pinion Nut
Figure 11— Removing the Pinion Flange

24. Bearing cups (3 and 7) from the axle housing using
D158 and C4307 (figure 12).
INSPECTION
Carefully and thoroughly inspect all drive unit parts
25. Pinion adjusting shims (4) and baffle (if used).
before reassembly.
• Keep the shims together. Thorough inspection of the drive parts for wear or
stress and subsequent replacement of worn parts will
26. Pinion inner bearing (3) using J 29721 and eliminate costly drive component repair after reassem
J 29721-70. (figure 13). bly.
AXLE HOUSING
CLEANING
Do not steam-clean drive parts that have ground and L* Inspect
polished surfaces such as gears, bearings, and shafts.
All parts should be disassembled before cleaning. • The axle housing bore for nicks or burrs that could
prevent the outer diameter of the pinion seal from
any burrs that are found.
dried with compressed air. Do not allow the bearings to • The housing for cracks. Replace the housing if any
spin while drying them with compressed air. cracks are found.
chips, dirt, or rust. Refer to “Cleaning.”
DIFFERENTIAL Install or Connect (Figures 2, 14, and 15)
D Inspect 1. Lubricate all parts with axle lubricant.

2. New side gear thrust washers (27) to the side
• Pinion gear shaft for unusual wear. gears (25).
• Pinion gear and side gear teeth for wear, cracks, 3. Side gears (25) to the differential case.
• Install the side gears on the same side as
removed.
• The fit of the side gears in the differential case.
• The fit of the side gears on the axle shafts. 4. Pinion gears (24) to the differential without the
• Differential case for cracks and scoring. thrust washers (26).
• All parts for wear and replace if necessary. A. Install the pinion gears to the side gears so the
holes in the pinion gears are 180 degrees
PINION AND RING GEAR
apart.
• Ring and pinion gears are matched sets and both
B. Rotate the pinion gears into place, and verify
are replaced any time a replacement of either is
that the pinion gears line up with the pinion
necessary.
shaft holes.
I5 Inspect 5. New pinion thrust washers (26).
Pinion and ring gear teeth for cracking, chipping, opening enough to slide in the pinion thrust
scoring, or excessive wear. washers.
Pinion gear splines for wear. 6. Pinion shaft (28).
Pinion flange splines for wear. • Align the roll pin holes in the case and shaft.
The fit of the pinion gear splines on the pinion
7. Roll pin (29) (figure 14).
flange.
The sealing surface of the pinion flange for nicks, A. Peen metal from the case over the lock pin in
burrs, or rough tool marks that could cause dam two places, 180 degrees apart.
age to the inside diameter of the seal and result in B. Make sure the mating surfaces of the differen
an oil leak. tial case and the ring gear are clean and free of
All worn or broken parts and replace if necessary. burrs.
8. Ring gear to the case (2).
BEARINGS
A. Align the holes in the case with the holes in the
Inspect ring gear.
B. Press the ring gear onto the case.
Bearings for smooth rotation after oiling them. 9. New ring gear bolts (23).
Bearing rollers for wear.
Bearing cups for wear, cracks, brinelling, and scor $ Tighten
ing.
A. Ring gear bolts in stages, gradually pulling the
Important ring gear onto the differential case.
B. Ring gear bolts in sequence to 298 N-m (220
When replacing worn or cracked bearings and lbs. ft.).
Ring gear and pinion gear for wear and replace
them as a set if worn.
Low mileage bearings may have small scratches

on the rollers and the bearing cups from the initial
preload. Do not replace a bearing for this reason.
SHIMS
I9 Inspect

shim.

Tools Required:
J 24385 Differential Case Spreader
D136/D346 Master Differential Bearings Figure 14—Installing the Roll Pin
10. Master differential bearings D136/D346 to the dif

ferential (figure 15).
• Refer to “Determining Total Shim Pack Size.”
• Outboard spacers, if used, should be in place.
DETERMINING TOTAL SHIM PACK SIZE
NOTICE: While both methods for setting dif

ferential bearing preload and gear backlash
are described. All Model 80 axle assemblies
may be serviced by using the outboard selec
tive shim method.
NOTICE: If the original axle assembly has the
outboard selective shims, it should not be
serviced using the inboard shim s for
preload/backlash adjusment. In otherwords, if
you have outboard selective shims, you must
stay with that method. If the axle assembly
uses inboard shims and outboard spacers
(non-selective), you may use the outboard
selective shim method for service.
Installed
NOTICE: If your axle assembly has selective
outboard spacers and one 0.76 mm (0.030
inch) shim (each side) between the differen
tial case and bearing cone. Make your mea
surem ents with the outb o ard spacers
removed, but with the 0.76 mm (0.030 inch)
shim assembled on the differential case trun
nion placed between the case and the master
differential bearings. The selective outboard
spacers are available in sizes (thickness)
from 5.18 mm (0.2040 inch) to 6.10 mm
(0.2400 inch), in 0.08 mm (0.003 inch) incre
ments. The dial indicator should have the
capability of making measurements up to
12.7 mm (0.500 inch).
NOTICE: If your axle assembly has outboard
spacers, but controls the preload and back
lash by using selective shims (each side)
between the differential case and bearing
cone. Make the measurements with the out
board spacers installed in the housing, but
do not place any shims on the differentail
case hubs between the case and master dif 5. Zero the dial indicator.
ferential bearings. The selective shims 6. Force the differential case in the opposite direction
placed between the bearing cone and differ as far as it will go. Repeat this step until the same
ential case are available in 0.08, 0.13, 0.25, reading is obtained. Record the number of thou
0 .7 6 .mm (0.003, 0.005, 0.010, 0.030 inch) sandths that the dial indicator traveled, not the
sizes. The dial indicator should have the reading on the dial. This will be the measurement
capability of making measurements up to of the shim pack without the bearing preload
3.81 mm (0.150 inch). (which will be added later).
7. Remove the dial indicator.
1. Assemble the case (22) to the axle housing. The
8. Remove the differential from the housing.
pinion must not be installed.
2. Mount a dial indicator having a minimum travel of 5 • Do not remove the master bearings from the
mm (0.200 inch) with a magnetic base on the ring differential.
gear bolt side of the housing (figure 16). 9. Remove the spacers from the housing, if used.
3. Force the differential assembly as far as possible in • NOTE: Spacers are removed to prevent them
the direction toward the indicator. from falling out while installing the pinion gear.
4. Preload the dial indicator one half of its travel. Tag spacers and indicate from which side they
Place the tip of the indicator on a flat surface on were removed. They must be reassembled as
the differential, next to a ring gear bolt. Mark this removed or the reading taken in step 7 will not
location with a piece of chalk. be correct.

Tools Required:
D 115 Dial Indicator
D 115-3 Arbor
6732 (or D 116-2) Master Discs
6738 (or D 6255) Master Pinion Block
6739 (or D 116-1) Pinion Height Block
6740 Adapter Cone
6741 Threaded Rod
C 4171 Handle
C 4204 Cup Installer (Inner Pinion Bearing Cup)
J 7818 Rear Pinion Bearing Cup Installer
NOTICE: The older Master Discs (D-116-2)

can be used with this gage set if available,
instead of the 6732.
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
D 6732
D 115-3
Figure 20— Dial Indicator On The Arbor
C. A negative (-) pinion marking indicates that the

distance between the ring gear centerline and
the pinion head must decrease by the number
of thousandths marked on the pinion. This
means that the shim pack will increase by the
same number of thousandths.
D. A pinion etched zero (0) will use the nominal
setting determined by this procedure.
10. After making the measurement, remove the gage
tools and the inner pinion bearing cone and cup.
11. Measure each shim separately with a micrometer
and add the dimensions together to obtain the total
shim pack thickness. If a baffle or slinger is used,
these also must be measured and included in the
shim pack.
PINION INSTALLATION
■n- Install or Connect (Figures 21 through 24)

Figure 22—Installing Inner Bearing
Tools Required: 4. Outer bearing cone (7), slinger, and oil seal, using
J 5590 Rear Pinion Bearing Cone Installer D 187-A pinion seal installer.
D 128 Dial Indicator Set or Equivalent • Apply a light coat of axle lubricant to the pinion
D 187-A Pinion Seal Installer seal lip.
C 4171 Handle 5. Preload shims (6) onto pinion gear.
C 4204 Rear Pinion Bearing Cup Installer 6. Pinion into the axle housing.
1. Place the required amount of shims (and baffle if 7. Pinion flange (10).
used) in the inner bearing bore. 8. Washer (11) and old nut (12).
2. Drive the inner bearing cup into the axle assembly
Tighten
using C 4171 and C 4204. The cup must be seated
on the shims (figure 21).
3. Inner bearing cone (and slinger if used) on pinion. • Nut (12) to 637 N-m (470 lbs. ft.) while holding
Drive the bearing cone onto the Pinion shaft using the pinion with J 8614-01 (figure 23).
J 5590 (figure 22). A. The nut until the pinion end play is just tak
en up. Rotate the pinion while tightening the
nut to seat the bearings. Once there is no
end play in the pinion, the preload torque
should be checked.
NOTICE: If your axle assembly has selective

outboard spacers and one 0.76 mm (0.030
inch) shim (each side) between the differen
tial case and bearing cone, make your mea
surem ents with the o u tb o ard spacers
removed, but with the 0.76 mm (0.030 inch)
shim assembled on the differential case trun
nion placed between the case and the master
differential bearing. The selective outboard
spacers are available in sizes (thickness)
from 5.18 mm (0.2040 inch) to 6.10 mm
(0.2400 inch), in 0.08 mm (0.003 inch) incre
ments. The dial indicator should have the
capability of making measurements up to
12.7 mm (0.500 inch).
NOTICE: If your axle assembly has outboard

spacers, but controls the preload and back
lash by using selective shims (each side)
between the differential case and bearing
Figure 23—Tightening Pinion Nut cone, make the measurements with the out
board spacers installed in the housing, but
B. Remove J 8614-01. Using an inch-pound do not place any shims on the differential
torque wrench, check the pinion preload by case hubs between the case and master dif
rotating the pinion with the wrench (figure ferential bearings. The selective shims
24). Preload should be at or below 2.8 to placed between the bearing cone and differ
5.1 N-m (25 to 45 lbs. in.) on new bearings, ential case are available in 0.08, 0.13, 0.25.
or 1.0 to 1.4 N-m (8 to 12 lbs. in.) for used 0.76.mm (0.003, 0.005, 0.010, 0.030 inch). The
bearings. dial indicator should have the capability of
C. Once the specified preload has been obtain making measurements up to 3.81 mm (0.150
ed, rotate the pinion several times to ensure inch).
the bearings have seated. Recheck the
1. Force the ring gear to mesh with the pinion. Rock
preload and adjust if necessary.
the ring gear to allow the teeth of the gears to
ASSEMBLING THE DIFFERENTIAL INTO THE AXLE mesh.
HOUSING 2. Assemble the differential (22) with master bearings
installed to the axle. The pinion must be installed.
Tools Required: 3. Mount a dial indicator with a magnetic base on the
J 8092 Driver Handle ring gear bolt side of the housing (figure 25).
J 23690 Differential Side Bearing Installer 4. Place the indicator tip on the chalk mark made
J 24385-01 Differential Carrier Spreader earlier.
D 136/D 346 Master Differential Bearings 5. With the force still applied to the differential case,
D 128 Dial Indicator Set or Equivalent set the dial indicator to zero.
Figure 24—Checking Pinion Preload Figure 25—Measuring Differential Movement

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
Figure 26— Installing Differential Bearings Figure 27—Mounting The Spreader

Figure 28—Measuring Backlash Figure 29—Gear Tooth Nomenclature
(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.
GEAR TOOTH TOOTH CONTACT
PATTERN CHECK
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.
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.
ring gear teeth using a medium stiff brush. FINAL ASSEMBLY
torque of 54-68 N-m (40-50 lbs. ft.) is required ■44- Install or Connect
to turn the pinion.
give a satisfactory pattern. Turn the companion Tighten
$
rotates one full revolution. Then reverse the Cover bolts (17) to 47 N-m (35 lbs. ft.
TOE TOE
HE HEEL A HEEL


CONDITION:
CORRECTION:
SERVICE HINTS:
3704r5056
Figure 30—Gear Tooth Patterns

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
SPECIAL TOOLS
1. D 116-2
2. D 115-3 11, J 8092
12. J 5590
D 116-1
4. D 115 13. J 8614-01
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
1. MASTER DISCS (MILLER) 10. FRONT PINION BEARING CUP INSTALLER

2. ARBOR, (MILLER) 11. DRIVER HANDLE
3. PINION HEIGHT BLOCK (MILLER) 12. REAR PINION BEARING CONE INSTALLER
4. SCOOTER GAGE (MILLER) 13. PINION FLANGE REMOVER
5. MASTER DIFFERENTIAL BEARINGS (MILLER) 14. DIFFERENTIAL SIDE BEARING INSTALLER
6. MASTER PINION BLOCK (MILLER) 15. DIFFERENTIAL SIDE BEARING REMOVER
7. CUP INSTALLER (MILLER) 16. DIFFERENTIAL CARRIER SPREADER
8. HANDLE (MILLER) 17. SIDE BEARING ADAPTERS
9. DIFFERENTIAL SIDE BEARING REMOVAL PLUG
V3951
LOCKING DIFFERENTIAL 4B7-1
SECTION 4B7
LOCKING DIFFERENTIAL
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.
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
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).
6. WASHER, PINION THRUST

A. GEAR, RING 7 1/2-INCH 7. GEAR, PINION 15. WASHER, WAVE
B. GEAR RING 8 1 /2 - INCH 8. WASHER, SIDE GEAR THRUST 16. PLATE, CAM
C. GEAR, RING 9 1/2-INCH 9. PLATES, CLUTCH 17. BLOCK, THRUST
1. CASE, DIFFERENTIAL 10. GEAR, SIDE 18. SHAFT, PINION
2. PIN, STOP (9 1/2 ONLY) 11. GOVERNOR 19. CLIP, GUIDE
3. SCREW, LOCK 12. PLATES, CLUTCH 20. CLIP, GUIDE
4. BUSHING, GOVERNOR 13. WASHER, SIDE GEAR THRUST 21. GEAR, SIDE CAM
5. BUSHING LATCHING BRACKET 14. SLEEVE, SIDE THRUST (9 1/2 ONLY) 22. RING, RETAINING
6404r5914
Figure 1—Differential Components

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
the side thrust sleeve (14) including the side gear
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.
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.
11. If the backlash is too low, use a thinner side gear

thrust washer.
• If the thrust block thickness is not 0.000 to 0.1524
Right Side Gear Backlash Adjustment
mm (0.000 to 0.006 inch) less than the side gear
1. Assemble the clutch plates. spread, adjust the clearance by:
• Alternate the plates as shown in figure 1.
A. Selecting a new thrust block the correct size to
2. Assemble the guide clips (19) to the plates.
obt ai n 0 . 0 0 0 to 0 . 1 5 2 4 mm ( 0 . 0 0 0 to
• Use grease in the clips to hold them in place on 0.006-inch) clearance.
the plates. B. Reshimming the right and/or left clutch plates.
3. Install the side gear thrust washer (8), clutch plate The backlash must be rechecked and adjusted
assembly (9), and right side gear to the differential. to specification if necessary.
4. Place the pinion gears (7) and thrust washers (6)
into the differential. ASSEMBLY OF THE DIFFERENTIAL
• Align them with the pinion shaft hole.
5. Press down on the side gear, and install the pinion
shaft (18) and lock screw (3).
1. Left side gear thrust washer (13).
• If the side gear cannot be pressed down far
2. Cam unit. Refer to “Cam Unit Assembly.”
enough to install the pinion shaft, use a thinner
3. Right side gear thrust washer (8).
side gear thrust washer.
4. Right clutch plates with guide clips (19).
6. Rotate the pinion gear closest to the lock screw so
that one of the teeth is pointing downward (perpen • Assemble alternately as shown in figure 1.
dicular to the ring gear flange). 5. Right side gear (10).
7. Insert a large tapered tool, like a screwdriver, firmly 6. Thrust block (17), pinion thrust washer (6), and
between the side gear and the pinion shaft. pinion gear (7).
8. Mount a dial indicator to the ring gear flange, and
A. Place the pinion gears into the differential 180
place the stem of the indicator on one of the teeth
degrees apart.
on the pinion gear closest to the lock screw (figure
B. Rotate the gears and thrust block into position.
5). C. The open side of the thrust block must face the
9. Pull the pinion gear firmly into its seat, and rotate
small window opening.
the gear back and forth while reading the dial indi
cator. Record the reading. 7. Pinion shaft (18).
10. Repeat steps 6 through 9 on the opposite pinion 8. A new lockscrew (3). Install finger tight.
gear. • Tighten to specifications after installed in the
11. The backlash should be between 0.051 and 0.243 vehicle.
mm (0.002 - 0.010 inch).
9. Governor assembly (11) and latching bracket (5).
12. If the backlash is too high, use a thicker side gear
thrust washer. • The straight end of the latching bracket spring
13. If the backlash is too low, use a thinner side gear must be over and outside the governor assem
thrust washer. bly shaft (figure 8).
Thrust Block Clearance Adjustment 10. Stop pin (2) (9 1/2-inch only).
• Press the pin flush with the case.
1. Left thrust washer (13) to the differential.

2. Cam unit to the differential.
3. Right side gear thrust washer (8) to the differential.
4. Clutch plates with guide clips to the differential.
• Assemble alternately as shown in figure 1.
5. Right side gear (10) to the differential.
6. Pinion shaft (18) and lock screw (3). Insert a large
tapered tool, like a screwdriver, firmly between
each side gear and the pinion shaft.
7. A 1-2 inch telescoping gage between the side gear
faces, not the gear teeth.
€ Measure
1. Measure the side gear spread (figure 6).

2. Remove the telescoping gage.
3. Measure the telescoping gage with a microme
ter.
4. Measure the original thrust block at the outer
corner with a micrometer (figure 7).
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
Figure 9— Differential Components
11. Governor bushing (4).

• Use the bushing with a straight hole, not a
tapered hole.
• Press the bushing in far enough to give 0.1016
to 0.508 mm (0.004 to 0.020 inch) shaft end
play.
12. Latching bracket bushing (5).
• Press in far enough to eliminate all end play.
Some 9 1/2-inch bushings have a tapered hole.
Do not use a straight bushing, use only a
tapered bushing.

DISASSEMBLY OF THE DIFFERENTIAL
Remove or Disconnect (Figures 9, 10, and 11)
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
Figure 11— Removing the Thrust Sleeve Figure 12—Cam Unit Components
2. Case screws (32). Important

• Set the unit on the right side case half.
3. Case halves (figure 10). • Do not replace the thrust sleeve unless neces
A. Pry the halves apart at the yoke hole location. sary.
B. Hold the side gear in the left side case half. Side gear bore for scoring. If scoring is present,
4. Governor assembly (48). replace the differential.
5. Latching bracket assembly (43).
6. Left side gear (46). Important
7. Left side clutch plates (44) and guide clips (47).
8. Left side gear thrust washer (45). • If any damage to the differential case is found,
9. Reaction blocks (41), pinion yoke (42), pinion gears the differential must be replaced.
(39), and pinion thrust washers (38).
10. Right cam unit from the differential. CAM UNIT ASSEMBLY
11. Right side gear thrust washer (36).
• Measure and record the overall length of the Install or Connect (Figures 9 and 12)
gear assembly from the front of the gear to the
back of the thrust sleeve (35) including the side 1. Cam plate (33) to the side cam gear (40).
gear thrust washer (36). 2. Wave washer (15).
3. Clutch plates.
12. Thrust sleeve (35) using J 22912-01.
• Press the sleeve from the side gear (figure 11). • Alternate the plates and position the wave
13. Clutch plates (37). washer as shown in figure 12.
14. Guide clips (34). 4. Thrust sleeve (35).
15. Wave washer (15).
16. Cam plate (33). • Press the thrust sleeve flush with the side gear
17. Side cam gear (40). disc spline.
CLEANING AND INSPECTION 5. Guide clips (34) to the plates.

• Use a chassis grease in the clips to hold them
|) y | Clean
in place on the plates.
• All parts with an approved solvent. A. If the side gear or thrust sleeve has been
replaced, measure and record the overall
FI Inspect length of the gear to the back of the thrust
sleeve (35) including the side gear thrust
• All parts for excessive wear and breakage. washer (36).
• Pinion gear and side gear teeth for wear, cracks, B. Compare this reading with the reading
scoring, and spalling. obtained earlier.
• Thrust washers for wear. C. If the new reading is more than 0.0762 mm
• The fit of the side gears on the axle shafts. (0.003 inch) higher or lower than the origi
• Differential case for cracks and scoring. nal, select a side gear thrust washer that will
• Thrust sleeve for excessive wear. return the reading closest to the original
• All parts and replace them if necessary. reading.
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.
Left Side Gear Backlash Adjustment

1. Assemble the clutch plates.
• Alternate the plates as shown in figure 12.
2. Assemble the guide clips (47) to the plates.
• Use grease in the clips to hold them in place on
the plates.
3. Install the side gear thrust washer (45), clutch plate
assembly (44), and left side gear to the differential.
4. Clamp the side gear in place using a set of wash
ers, a nut, and a bolt long enough to hold the side
gear in place (figure 13).
5. Place the pinion gears and pinion thrust washers
on the pinion yoke.
6. Install the yoke firmly to the differential case half.
7. Loosen the nut and index one pinion gear tooth to
point downward (perpendicular to the case half
face). Tighten the nut.
Figure 14—Installing the Pinion Yoke Figure 15—Measuring Backlash

8. Mount a dial indicator on the case half face using a

magnetic base (figure 15).
9. Place the stem of the dial indicator on the pinion
gear tooth.
10. Pull the pinion gear firmly into its seat, and rotate
the gear back and forth while reading the dial indi
cator. Record the reading.
• Do not unseat the pinion yoke. This will make
the backlash reading inaccurate.
11. Repeat steps 7 through 10 on the other 2 pinions.
12. The backlash should be between 0.051 and 0.254
mm (0.002 and 0.010 inch).
13. If the backlash is too high, use a thicker pinion
thrust washer.
14. If the backlash is too low, use at thinner pinion
thrust washer.
Reaction Block Clearance Adjustment
+ 4- Install or Connect (Figures 16 and 17)

Figure 16—Side Gear Spread
1. Left side gear thrust washer, clutch plates, and side
gear. Bolt them into position. Refer to “Left Side
Gear Backlash Adjustment.”
2. Right side gear thrust washer and cam assembly.
Bolt them into position. Refer to “Right Side Gear
Backlash Adjustment.”
* Measure
1. The distance from the side gear face to the case

half face (figure 16).
A. The thickness of the straight edge must be sub
tracted from the reading.
B. Add the measurement of both sides together.
This is the side gear spread.
2. The thickness of the original reaction blocks and
reaction block thrust washers together (figure 17).
3. If the combined reaction block and thrust washer
thickness is not 0.000 to 0.1524 mm (0.000 to
0.006 inch) less than the side gear spread, adjust
the clearance by:
• Selecting new reaction block thrust washer of
the correct thickness to obtain 0.000 to 0.1524 4. Left thrust washer (45).
mm (0.000 to 0.006 inch) clearance.
• Assemble the plates as shown in figures 9 and
• Reshim the left and/or right clutch disc pack.
12 .
The side gear backlash must be maintained.
Refer to “Right Side” and/or “Left Side Gear 5. Left side gear (46).
Backlash Adjustment” in this section. 6. Latching bracket assembly (43).
• Some older locking differentials had select 7. Governor assembly (48).
fit reaction blocks without the thrust washer
between them. These models require replac • The straight end of the latching bracket spring
ing the reaction blocks with the correct thick must be over and outside the governor assem
ness reaction block. bly shaft.
ASSEMBLY OF THE DIFFERENTIAL 8. Case halves (31) together.

• Hold the side gear in the left side case half.
9. Case screws (32).
1. Right thrust washer. 10. The ring gear and differential side bearings. Refer
2. Right cam unit. Refer to “Cam Unit Assembly. ” to “Assembly of the Rear Axle” under the “10
3. Reaction blocks (41), reaction block thrust washer, 1/2-Inch Ring Gear” heading.
pinion yoke (42), pinion gears (39), and pinion
thrust washers (38).
SPECIFICATIONS
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
— — 0.042-inch 0.035-inch
0.052-inch 0.052-inch 0.052-inch
LUBRICATION
Lubricant .................................. 80W90 GL-5
(Do not use limited slip additive)
T3324
SPECIAL TOOLS
NOTES
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1-1
SECTION 4C1
7 1/4-INCH RING GEAR AND

ALL WHEEL DRIVE FRONT AXLE
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.
DISASSEMBLY OF THE AXLE

INSPECTION 6. Right seal and bearing, using J 29369-2 and
J 23907 (figure 4).
Perform the following checks before disassembling
7. Seal from the tube. Pry out with a screwdriver.
the axle.
8. Thrust washer.
1. Remove the axle cover and drain the lubricant. 9. Sleeve and output shaft.
2. Check the ring gear backlash. Refer to “BACK
10. Differential pilot bearing from the output shaft,
LASH ADJUSTMENT.” This information can be
using J 34011 (figure 5).
used to determine the cause of the axle problem. It
11. Washer.
will also help when setting up the shim packs for
12. Shaft, and deflector.
locating and preloading the differential case.
3. Inspect the case and oil for metal chips. Determine • Using J 2619-01, pull the output shaft out of the
where the metal chips came from, such as a bro case (figure 6).
ken gear or bearing cage.
4. Determine the cause of the axle problem before 13. Bolts and cover.
disassembly, if possible. 14. Left seal.
15. Bolts.
DISASSEMBLY 16. Separate the carrier case.
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.
Figure 1—4X4 Front Axle Components

F7475
Figure 2—AWD Front Axle Components

1. Shaft 16. Spring 31. Insert 46. Nut

2. Deflector 17. Shift Shaft and Fork 3Z Sleeve 47. Plug
3. Seal 18. Bolt 33. Side Bearing 48. Bushing
4. Bearing 19. Lock Tab 34. Bolt 49. Vent Hose
5. Tube 20. Thrust Washer 35. Differential Case 50. Vent
6. Bolt 21. Differential Pilot Bearing 36. Bolt 51. Fitting
7. Thrust Washer 22. Sleeve 37. Ring and Pinion Gears 52. Shaft
8. Retaining Ring 23. Output Shaft 38. Shim 53. Thrust Washer
9. Carrier Connector 24. Washer 39. Bearing 54. Side Gear
10. Shift Cable 25. Plug 40. Spacer 55. Thrust Washer
11. Shift Cable Housing 26. Washer 41. Bearing 56. Differential Pinion
12. Gasket 27. Pin 42. Seal Gear
13. Indicator Switch 28. Bolt 43. Deflector 57. Cover
14. Spring 29. Carrier Case 44. Flange 58. Bolt
15. Seal 30. Bearing 45. Washer 59. Shaft
F1388
Figure 3—Axle Components - Legend
J 34011
Figure 4— Removing the Axle Tube Bearing and Seal Figure 5—Removing the Output Shaft Pilot Bearing
27. Bearing and seal using J 33837-1, J 33837-3, and

J 33837-6.
A. Insert J 33837-6 into the pinion bore.
B. Thread the forcing screw (J 33837-3) into
J 33837-6.
C. Turn the forcing screw to pull the parts from the
case.
28. Inner bearing cup by pushing it out using
J 33837-1, J 33837-3, and J 33837-6 (figure 14).
29. Bolt and shaft from the differential case.
30. Differential pinion gears and thrust washers.
31. Side gears and thrust washers.
• Mark the side gears and case so they can be
reinstalled in their original location.
32. Bolts.
33. Ring gear.
• Do not pry between the ring gear and the case.
Drive the gear off with a brass drift and ham
mer.
34. Side bearings, using J 22912-01 (figure 15). Figure 6— Removing the Output Shaft
35. Bushings. Use J 33791 (figure 16 and 17).
Figure 7— Separating the Carrier Case Halves Figure 10— Remove the Sleeve Bearing
Figure 8— Removing the Lock Tabs
J 33837-1
Figure 9— Removing the Side Bearing Cup Figure 12—Remove the Pinion Flange
Figure 13— Removing the Pinion Bearing
ALL WHEEL DRIVE (AWD) FRONT AXLE
* Disassemble (Figures 2 through 17)
Tools Required:
J 2619 Slide Hammer
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.
3. Tube. 17. Spacer from the pinion.

4. Right seal and bearing, using J 29369-2 and 18. Bearing from the pinion. Use J 22912-01 and a
J 29307 (figure 4). press (figure 13).
5. Shaft, and deflector. 19. Shim.
• Use J 2619-01 and J 21579 to pull the output 20. B earing, cup, and s e a l, using J 3 3 8 3 7 -1 ,
shaft from the carrier (figure 6). J 33837-3, and J 33837-6.
6. Bolts and cover. A. Insert J 33837-6 into the pinion bore.
7. Left seal. B. Thread the forcing screw (J 33837-3) into
8. Bolts. J 33837-6.
9. Separate the carrier case. C. Turn the forcing screw to release the parts from
• Insert a screwdriver into the slots provided and the case.
pry to separate the case (figure 7). 21. Inner bearing cup by pushing it out using
10. Differential case. J 33837-1, J 33837-3 and J 33837-6 (figure 14).
11. Bolts and lock tabs from the side bearing adjuster 22. Bolt and shaft from the differential case.
sleeves (figure 8). 23. Differential pinion gears and thrust washers.
12. Bearing cups and sleeves from the case. 24. Side gears and thrust washers.
• Turn the sleeves using J 33792 until the cups • Mark the side gears and case so they can be
are pushed out of the case (figure 9). reinstalled in their original location.
13. Bearing from the sleeve. Use J 21551 (figure 10). 25. Bolts.
14. Pinion flange nut and washer using J 8614-01 (fig 26. Ring gear.
ure 11). • Do not pry between the ring gear and case.
• Mount the left carrier case half in J 33837-1 Drive the gear off with a brass drift and ham
(figure 12). mer.
15. Flange and deflector using J 33837-1 and 27. Side bearings, using J 22912-01 (figure 15).
J 33837-3 (figure 12). 28. Bushings. Use J 33791 (figure 16 and 17).
16. Pinion, with spacer, bearing and shim.
CLEANING AND INSPECTION

DIFFERENTIAL
CLEANING
Do not steam clean drive parts having ground and Inspect
polished surfaces such as gears, bearings, and shafts.
• Pinion gear shaft for unusual wear.
All parts should be disassembled before cleaning.
scoring, spalling.
cleaning. Use soft, clean, lintless rags. Parts may be • The fit of the side gears in the differential case.
dried with compressed air. Do not allow the bearings to • Fit of the side gear on the axle shafts.
spin while drying them with compressed air. • Differential case for cracks and scoring.
• All parts for wear and replace if necessary.
INSPECTION RING AND PINION GEAR
It is critical to carefully and thoroughly inspect all • Ring and pinion gears are matched sets and both
drive unit parts before assembly. are replaced any time a replacement of either is
Thorough inspection of the drive parts for wear or necessary.
stress and subsequent replacement of worn parts will Inspect
I?
eliminate costly drive component repair after reassem
bly. Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.
AXLE HOUSING Pinion splines for wear.
Pinion flange splines for wear.
I? Inspect The fit of the pinion gear on the pinion flange.
The sealing surface of the pinion flange for nicks,
Axle housing bore for nicks or burrs that would burrs, or rough tool marks which would cause dam
prevent the outer diameter of the pinion seal from age to the seal’s inside diameter and result in an
sealing. Remove any burrs that are found. oil leak.
Bearing cup surfaces for nicks or burrs. Remove All worn or broken parts and replace if necessary.
any burrs that are found. Important
Housing for cracks. Replace the housing if any
cracks are found. A new pinion flange must be replaced v/hen the
Housing for foreign material such as metal chips, ring gear and pinion gear are replaced to main
dirt, or rust. Refer to “CLEANING.” tain proper system balance.
BEARINGS • Adjuster sleeves for damaged threads. Replace if

required.
V Inspect
SHIFT MECHANISM (PART-TIME AXLE ONLY)
Bearings for smooth rotation after oiling them.
Bearing rollers for wear.
Bearing cups for wear, cracks, brinelling, and scoring. Inspect (Figure 1 and 3)
Important Carrier connector for damaged splines and teeth.

Replace as required.
• When replacing worn or cracked bearings and
cups, make sure to replace them in sets Shift fork for wear, scoring, and damage to thrust
• Low mileage bearings may have very small surfaces. Replace if needed.
scratches and pits on the rollers and bearing Sleeve and inner output shaft for damaged splines
cups from the initial preload. Do not replace a and teeth. Replace if necessary.
bearing for this reason. Spring for breakage.
THRUST WASHERS, SHIMS, AND ADJUSTER
SLEEVES Important
I? Inspect • Lubricate all seal lips, bearings, gears, and

bearing surfaces with axle lubricant prior to
• Shims and thrust washers for cracks and chips.
assembly.
Damaged shims should be replaced with an
equal-size service shim.
ASSEMBLY OF THE AXLE

DIFFERENTIAL CASE ASSEMBLY PINION BEARING
+4- Install or Connect (Figures 1 through 3 and
CUP INSTALLATION
18)
+4- Install or Connect (Figures 1 through 3, 19
Tool Required: and 20)
J 33790 Side Bearing Installer
1. Thrust washers and side gears into the differential Tool Required:
case. J 33837 Pinion Bearing Remover and Installer
• If the original gears and washers are being
reused, install them on the same side from 1. Outer Bearing into the case using J 33837-1
which they were removed. J 33837-3, and J 33837-4 (figure 19).
2. Pinion gears. 2. Inner Bearing into the case using J 33837-1
• Position one pinion gear between the side J 33837-3, and J 33837-4 (figure 20).
gears and rotate the gears until the pinion gear
is directly opposite the opening in the case.
• Place the other pinion gear between the side
gears, making sure the hole in both pinion
gears line up.
3. Thrust washers.
• Rotate the pinion gears toward the opening
enough to permit the sliding in of the thrust
washers.
4. Shaft and bolt.
5. Ring gear onto the differential case.
6. Bolts.
Important
Always install new bolts. Never reuse the old

bolts.
$ Tighten
• Bolts in progressive steps to 80 N-m (59 lbs. ft.).

7. Side bearings, using J 33790 (figure 18). Figure 18—Installing the Differential Side Bearings

Tools Required
J 33838 Pinion Depth Setting Gage
1. Pinion depth is adjusted by selecting a shim of the
proper thickness.
2. Lubricate the inner and outer pinion bearings liber
ally with axle lubricant.
3. Hold the pinion bearings in position and install
J 33838 and J 29763 (figure 21 and 22).
• Set the dial indicator at ZERO, then position it
in J 33838. Push the dial indicator downward
until the needle rotates approximately 3/4 turns
to the right.
4. Tighten the dial indicator in this position.
5. Set the button of J 33838 on the differential bear
ing bore (figure 21).
6. Rotate the tool slowly back and forth until the dial
indicator reads the lowest point of the bore. Set the
dial indicator to ZERO. Repeat the rocking action
of the tool to verify the ZERO setting.
7. After the ZERO setting is obtained and verified,
move the tool button out of the differential side
bearing bore (figure 22). Record the dial indicator
reading.
8. The dial indicator reading is equal to the required
shim size.
Example: If the dial indicator reads 0.84 mm
(0.003 inch) in step 8, a 0.84 mm (0.003 inch) shim
is required. Available shim sizes are listed in
“SPECIFICATIONS.”
9. Remove tools and bearing cones.
in Bearing Bore Out of Bearing Bore

7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C 1-11
PINION INSTALLATION
+«- Install or Connect (Figure 1 through 3, 11, 23,
24 and 25)
J 33785
Tools Required:
J 33785 Bearing Installer
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
• Pinion bearing preload. Use an inch-pound torque

wrench (figure 25).
• The correct preload is 1.7-2.8 N-m (15-25 lbs. in.).
1. Rotate the pinion with the torque wrench and
observe the reading.
2. If the preload torque is below specifications, contin
ue torquing the pinion nut in small increments.
Check the preload after each tightening. Each tight Figure 24— Installing the Pinion Seal
ening increases the bearing preload by several
inch pounds. If the bearing preload is exceeded,
the pinion will have to be removed, and a new
collapsible spacer installed.
3. Once the preload has been obtained rotate the pin
ion several times to make sure that the bearings -
have seated. Recheck the preload, and adjust if
necessary.
Figure 25—Measuring Pinion Bearing Preload

DIFFERENTIAL ASSEMBLY
INSTALLATION
Install or Connect (Figures 1 through 3, 26
and 27)
Tools Required:
J 23423-A Bearing Cup Installer
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 8001-1 Dial Indicator Clamp
1. Tighten the right sleeve to 140 N m (103 lbs. ft.)
2. Tighten the left sleeve to 140 N-m (103 lbs. ft.)
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
• If the backlash is incorrect, adjust the sleeves

as necessary. Always maintain one notch
preload on the side bearings.
EXAMPLE: If it is necessary to turn the right
sleeve in one notch, the left sleeve must be
turned OUT one notch.
• To increase backlash, turn the left sleeve in,
and the right sleeve out, an identical amount.
To decrease backlash, turn the right sleeve in,
and the left sleeve out, an identical amount.
13. When the backlash is correct, mark the position of
the sleeves so they can be kept in the same loca
tion.
GEAR TOOTH CONTACT

PATTERN CHECK
Gear— AWD Only ously outlined. It is a method to verify the correct
pinion for low noise level and long life can be ensured.

TEST
Flange
11. Divide the dial indicator reading by 2 to obtain the

actual backlash.
EXAMPLE: A dial indicator reading of 0.16 mm
(0.006 inch) means that there is actually 0.08-mm
(0.003-inch) backlash.
ing backlash.
• If the backlash varies more than 0.05 mm
(0.002 inch), check for burrs, a distorted case
flange, uneven bolting conditions, or foreign
matter between the case and the ring gear.
• Gear backlash should be between 0.08 to 0.25
mm (0.003 to 0.010 inch) with a preferred spec
ification of 0.013 to 0.018 mm (0.005 to 0.007
inch).
4C1 -14 7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE

to turn the pinion.
compare with figures 32 through 34.
ADJUSTMENTS AFFECTING TOOTH CONTACT
Two adjustments can be made which will affect the
tooth contact pattern. These are backlash and pinion
depth. The effects of bearing preloads are not easily
seen on hand loaded teeth pattern tests. These adjust
with the backlash and the drive pinion adjustments.
It may be necessary to adjust both pinion depth and
Figure 32— Pinion Gear is too Far Away from Ring backlash to obtain the correct pattern.
Gear The position of the drive pinion is adjusted by increas
ing or decreasing the shim thickness between the pinion
head and the inner race of the rear bearing. The shim is
used in the differential to compensate for manufacturing
tolerances. Increasing the shim thickness will move the
pinion closer to the centerline of the ring gear.
Backlash is adjusted by the side bearing adjusting
sleeves which move the case and ring gear assembly
closer to, or further from the drive pinion. (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 amount. To decrease back
lash, turn the right sleeve in and turn the left sleeve out
an identical amount.
Important
• The contact pattern should be located in the middle

of the ring gear teeth face (figure 33).
FINAL ASSEMBLY
PART-TIME FRONT DRIVE AXLE
Figure 33— Gear Tooth Contact Pattern Is Correct
«-+ Remove or Disconnect (Figures 1 and 3)
1. Four case bolts.

2. Right carrier case half.
]*2*l Clean
• Sealing surfaces on the carrier case halves.

Remove all oil and grease. Use a chlorinated sol
vent, such as carburetor cleaner.
Install or Connect (Figures 1 and 3, 16, 17, 35

through 38)
Tools Required:
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.
2. Right carrier case.

3. Bolts.
£ Tighten

• Make sure the sleeves are in the proper position,
as marked previously.
4. Bolts and locks.
$ Tighten
• Bolts to 8 N-m (71 lbs. in.).

5. Left seal to the cover. Fully support the seal bore
area of the cover while installing the seal.
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
• Bolts to 25 N m (18 lbs. ft.).

7. Shaft with deflector. Tap into place.
8. Bearing. Use J 33844.
9. Seal. Use J 33893 (figure 35).
10. Seal. Use J 33799 (figure 36).
11. Differential pilot bearing. Use J 33842 (figure 37).
12. Washer to the output shaft.
13. Output shaft to the carrier assembly.
14. Sleeve.
15. Thrust washer. Use grease to hold it in place.
Figure 37— Installing the Differential Pilot Bearing
Figure 35— Installing the Shaft Seal Figure 38— Installing the Thrust Washer
16. Spring and shift shaft with fork.

17. Thrust washer. Use grease to hold it in place. Align
the notch and tab (figure 38).
18. Shaft to the tube.
19. Carrier connector with retainer ring. Tap into place.
A. Remove all oil and grease from the tube and
carrier gasket surfaces. Use carburetor cleaner
or equivalent.
B Apply sealer (GM P/N 1052357) or equivalent
to the carrier.
20. Tube assembly to the carrier.
21. Two upper bolts. Leave finger tight.
22. Shift cable housing and remaining bolts.
$ Tighten

inspect (Figure 39) Figure 39— Checking the Shift Mechanism
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
4* + Remove or Disconnect (Figures 2, 3, and 40)
1. Four case bolts (figure 40).

JQi Clean
• Sealing surfaces on the carrier case halves.

Remove all oil and grease. Use a chlorinated
solvent, such as carburetor cleaner. Figure 40— Carrier Case Bolts Installed
+ 4- & Tighten
Install or Connect (Figures 2, 3, 16, 17 and 35)
• Bolts to 8.0 N-m (71 lbs. in.).

Tools Required:
J 33844 Bearing Installer 5. Left seal to the cover . Fully support the seal bore
J 33893 Axle Seal Installer area of the cover while installing the seal.
J 33791 Case Bushing Installer
PQH Clean
1. Apply a bead of sealer (GM P/N 1052357) or
equivalent to one carrier case surface. Follow the • All oil and grease from the cover and carrier
sealer manufacturer’s instructions to apply the sealing surfaces. Use carburetor cleaner or
sealer. equivalent.
2. Right carrier case. 6. Apply sealer (GM P/N 1052357) or equivalent to
3 Bolts. the cover.
7 Cover and bolts.
$ Tighten
& Tighten
A. Bolts to 47 N m (35 lbs. ft.).
B, Make sure the sleeves are in the proper posi • Bolts to 25 N m (18 lbs. ft.).
tion, as marked previously.
8. Shaft with deflector. Tap into place.
4. Bolts and locks. 9. Bearing. Use J 33844.
10. Seal. Use J 33893 (figure 35). Tighten

A. Remove all oil and grease from the tube and
carrier gasket surfaces. Use carburetor cleaner • Bolts to 48 N-m (35 lbs. ft.).
or equivalent.
B. Apply sealer (GM P/N 1052357) or equivalent 13. Shaft.
to the carrier.
• Tap into place with a soft-faced hammer.
11. Housing to the carrier.
12. Bolts. 14. Bushings. Use J 33791 (figure 16 and 17).
DRIVE AXLE ASSEMBLY

OUTER DEFLECTOR RING
Remove or Disconnect (Figures 41 through • Do not cut through seal and damage sealing
45) surface of C/V outer housing with the chisel.
1. Clamp the axle shaft in a vise. 2. Small seal-retaining clamp on axle shaft with side
• Use soft metal or wood to protect the shaft. cutter, and discard.
2. Deflector ring from C/V outer race with a brass drift 3. Separate joint seal from C/V joint race at large
and hammer as shown and discard (figure 42). diameter, and slide seal away from joint along axle
shaft.
Install or Connect 4. Wipe excess grease from face of C/V inner race.
5. Spread ears on race retaining ring with J 8059 as
1. Position and square up deflector ring at press shown and remove C/V joint assembly from axle
diameter of C/V outer race. shaft.
2. Using a (1) 3-inch pipe coupling^ (2) fabricated 6. Seal from axle shaft.
sheet metal plate, and (3) M24 x 2.0 nut, as shown 7. Disassemble joint, and flush grease before installing
in figure 44, tighten nut until deflector bottoms new seal. Refer to “OUTER JOINT ASSEMBLY.”
against shoulder of C/V outer race.
ABS SENSOR RING
REPLACEMENT 1. Small seal-retaining clamp on neck of new seal. Do
not crimp.
Remove or Disconnect (Figures 43 and 44) 2. Slide the seal onto axle shaft and position neck of
seal in seal groove on axle shaft.
Tools Required: 3. Crimp seal-retaining clamp with J 35910 to 136
J 39245-1 Sensor Ring Installer N-m (100 lbs. ft.) (figure 47).
J 39245-2 Sensor Ring Spacer 4. Place approximately half of the grease provided
1. Deflector ring from C/V outer race and discard (fig inside the seal and pack C/V with remaining
ure 43). grease.
2. Sensor ring with a drift (figure 43). 5. Pinch swage ring by hand slightly to distort into
Install or Connect oval shape and slide onto large diameter of seal.
6. Push C/V joint onto axle shaft until retaining ring is
1. Light film of oil onto the inside of the sensor ring. seated in groove on axle shaft (figure 46).
• Ring must face with chamfer side up. 7. Slide large diameter of seal with large swage ring
2. Sensor ring with J 39245. in place over outside of C/V joint race and locate
3. Deflector ring. seal lip in housing groove.
• Position and square up the deflector ring at the
press diameter of the outer race.
• Using a 3 inch pipe coupling (K1-K2 models),
M24 x 2.0 nut, and fabricated sheet metal sleeve • Seal must not be dimpled, stretched or out of
as shown in figure 46, tighten nut until deflector shape in any way. If seal is not shaped correct
bottoms against shoulder of C/V outer race. ly, carefully insert a thin, flat, blunt tool (no
sharp edges) between large seal opening and
OUTER JO IN T SEAL outer race to let air escape. Shape seal proper
ly by hand and remove tool.
Remove or Disconnect (Figure 41 and 45)
8. Mount J 36652-1 swage clamp tool in vise and pro
Tools Required: ceed as follows:
J 8059 Snap Ring Pliers A. Position outboard end of axle assembly in tool.
J 35910 Seal Clamp Tool B. Place top half of proper size tool on lower half
J 36652 Swage Clamp Tool of tool and check for proper alignment (figure
1. Large swage ring from C/V joint using a chisel and 48 and 49).
discard. C.Inserts bolts and tighten by hand until snug.
1. ASSEMBLY, TRI-POT HOUSING

2. RING, SHAFT RETAINING
3. SPIDER, TRI-POT JOINT
4. RING, NEEDLE RETAINER
5. RETAINER, NEEDLE
6. BALL, TRI-POT JOINT
7. ROLLER, NEEDLE
8. RING, SPACER
9. RING, SWAGE
10. SEAL, TRI-POT JOINT
11. CLAMP, SEAL RETAINING
12. SHAFT, AXLE
13. SEAL, C/V JOINT 17. CAGE, C/V JOINT
14. RING, RACE RETAINING 18. RACE, C/V JOINT OUTER
15. BALL 19. RING, SENSOR
16. RACE, C/V JOINT INNER 20. RING, DEFLECTOR
F6721
Figure 41—Front Drive Axle Components

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).
Figure 52—Separating Inner Race and Cage Figure 53—Removing Spider Assembly
C. Make sure the retaining ring side of the inner

race faces out.
2. Balls.
A. Tap on the cage with a brass drift to tilt it
enough to install the balls.
B. Pack the inner joint with chassis grease.
Important
• Be sure that retaining ring side of inner race

faces axle shaft.
3. Install outer joint seal. Refer to “OUTER JOINT
SEAL” in this section.
J 8059
INNER TRIPOT SEAL
Remove or Disconnect (Figures 41, 47, and 53
through 56)
Figure 54— Installing Spider Assembly
Tools Required:
J 8059 Snap Ring Pliers
J 35910 Seal Clamp Tool
1. Retaining clamp protector from larger seal retaining
clamp (if so equipped).
2. Larger seal retaining clamp from tripot joint, using
chisel, and discard.
Important
• Do not cut through seal and damage sealing

surface of tripot outer housing with chisel.
3. Small seal-retaining clamp from axle shaft with side
cutter, and discard.
4. Seal from tripot housing by separating at large
diameter and sliding seal away from joint along
axle shaft.
5. Tripot housing from spider and shaft.
6. Spread spacer ring with J 8059 and slide spacer
ring and tripot spider back on axle shaft (figure 54).
7. Shaft retaining ring from groove on axle shaft and
slide spider assembly off of shaft.
3. Crimp seal retaining clamp with J 35910 to 136

N-m (100 lbs. ft.) as shown in figure 47.
4. Spacer ring on axle shaft and beyond second
groove.
5. Slide tripot spider assembly against spacer ring on
shaft.
V Important
• Be sure that counterbore face of tripot spider

faces end of shaft.
6. Install shaft retaining ring in groove of axle shaft
with J 8059.
7. Slide tripot spider towards end of shaft and reseat
spacer ring in groove on shaft (figure 54).
8. Place approximately half of grease provided in seal
kit and use remainder to pack tripot housing.
9. Position larger clamp on seal.
10. Slide tripot housing over tripot spider assembly on
shaft (figure 55).
Inspect 11. Slide large diameter of seal), with larger clamp in
place, over outside of tripot housing and locate
• Tripot balls and needle rollers for damage and seal lip in housing groove.
wear. 12. Position the tripot assembly at the proper vehicle
dimension shown in (figure 56).
Important
Important
• Handle the tripot spider assembly with care. Tripot
balls and needle rollers may separate from spider • Seal must not be dimpled, stretched or out of
trunnions. shape in any way. If seal is not shaped correct
ly, carefully insert a thin, flat, blunt tool (no
8. Remove spacer ring and seal from axle shaft. sharp edges) between large seal opening and
9. Flush grease from tripot housing. housing to let air escape. Shape seal properly
by hand and remove tool.
L* Inspect
13. Crimp seal retaining clamp with J 35910 to 176
N-m (130 lbs. ft.).
Joint seal
Spider
Important
Housing
Tripot balls
Needle rollers • Make sure that seal, housing and large clamp
All parts above for wear or damage and replace all remain in alignment while crimping.
them if necessary. 14. Retaining clamp protector over larger seal retaining
clamp and snap into position (if equipped).
0 Install or Connect
1. Small seal-retaining clamp on neck of seal. Do not

crimp.
2. Slide seal onto shaft and position neck of seal in
groove on axle shaft.
7 1/4-INCH RING GEAR AND ALL WHEEL DRIVE FRONT AXLE 4C1 -23
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 —

Pinion Shim Kits.............................................................................................................................. 0.53-0.64 mm
0.66-0.79 mm
0.81-0.94 mm
PINION PRELOAD AND BACKLASH

Pinion Preload, ................................................................................. 1.7-2.8 N m (15-25 lbs. in.)
Backlash......... ................................................................................. 0.08-0.25 mm (0.003-0.010-inch)
(Preferred) ................................................................................. 0.13-0.18 mm (0.005-0.007-inch)
LUBRICATION
Capacity........... .....................................................................................................................1.2 Liters (2.6 Pints)
Type................. ...........................................................................................SAE 80-W-90 GL-5 Gear Lubricant
T2378
SPECIAL TOOLS
1. J 21551 12 . J 8614-01
2. J 29763 13. J 33844
3. J 33782 14. J 33893
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.
11. 9. Bearing Cup Installer

10. Pinion Bearing Cup Remover and Installer
11. Pinion Shim Setting Gage
1. Output Shaft Bearing Remover 13. Axle Tube Bearing Installer
2. Dial Indicator 14. Output Shaft Seal Installer
3. Pinion Oil Seal Installer 15. Countshaft Roller Bearing Remover
4. Pinion Bearing Installer 16. Slide Hammer
5. Output Shaft Bearing Installer 17. Bushing Remover
6. Differential Side Bearing Installer 18. Dial Indicator Set
7. Side Bearing Adjuster Wrench 19. Dial Indicator Stand
8. Differential Side Bearing Installer 20. Clamp Swage Tool Set
F7518
8 1/4 AND 9 1/4-INCH RING GEAR 4C2-1
SECTION 4C2
8 1/4 AND 9 1/4-INCH RING GEAR

be used. Fasteners that are not reused, and those requiring thread locking compound will be called out
are not followed, parts or system damage could result
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 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
Figure 2— Left Output Shaft (K1, K2 Models) Figure 4— Pinion Gear
Figure 3—Right Output Shaft Figure 5— Differential Case and Bearings
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).
Figure 6—Ring Gear and Differential Case Bearings
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.
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
drive component repair after reassembly.
AXLE HOUSING • Thrust washers for wear.
• The fit of the differential side gears in the differen
I9 Inspect tial case.
• 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.
• 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.”
Figure 16—Removing the Pinion Nut and Flange
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.
Figure 18— Removing the Pinion Bearing
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.
J 36616
Figure 22—Removing the Pin (K1, 2 Models) Figure 24— Installing the Carrier Bushings
J 36616
Figure 23—Removing the Carrier Bushings
ASSEMBLY OF THE AXLE

Important 1. Outer bearing cup. Use the forcing screw and
J 36598-3 (T, K1 and K2) or J 36598-4 (K3) (figure
• Apply axle lubricant to all bearings, seal lips, gears, 25).
thrust washers, and bearing surfaces at assembly. 2. Inner bearing cup.
PINION BEARING CUP A. Remove J 36598-3 or J 36598-4 from the forc

ing screw.
INSTALLATION B. Place pilot J 36598-15 in the pinion seal bore.
C. Extend the forcing screw through the pinion
Install or Connect (Figures 1 through 9, 25,
bore.
and 26) D. Install J 36598-3 (T, K1 and K2 models) or
J 36598-4 (K3 models) on the forcing screw
Tool Required:
(figure 26).
J 36598 Holding Fixture and Pinion Service Tool
E. Rotate the forcing screw until the installer is
• Mount the left carrier case in J 36598. Use the
snug against the bearing cup.
J 36598-6 adapter plate for T, K1 and K2 models.
Tighten the attaching bolts securely.
Figure 25— installing the Outer Pinion Bearing Cup Figure 27—Measuring Pinion Depth-Button Located
in Bearing Bore
Figure 26— Installing the Inner Pinion Bearing Cup

F. Rotate the tool several times to make sure the Figure 28— Measuring Pinion Depth-Button Moved
bearing cup is not cocked in the bore. Out of 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
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.
J 3 6 6 0 1 -4
J 3 6 6 0 1 -3
Figure 29—Measuring Pinion Depth Figure 30—Installing the Pinion Bearing
13. After the ZERO setting is obtained and verified,

grasp the gaging arm by the flats and move the
tool button out of the differential side bearing bore
(figure 28). Record the dial indicator reading.
14. The dial indicator reading is equal to the required J
shim size. Example: If the dial indicator reads
0.508 mm in step 8, a 0.508 shim is required.
Available shim sizes are listed in “SPECIFICA
TIONS.”
two-step procedure. Both procedures must
be performed to ensure proper axle perfor
A. Setup dimension arrived at with the indica
tor is to be considered a starting point.
B. Gear tooth pattern check is necessary to
“fine-tune” the pinion depth and may indi
cate additional shim changes to the pinion
stem.
15. Remove the tool and bearing cones. Figure 31—Installing the Pinion Seal
PINION INSTALLATION 7. Deflector, flange, washer, and nut.

• Apply PST Sealant (GM P/N 1052080) or equiv
+ 4- Install or Connect (Figures 1 through 9, 16, alent to the pinion gear threads and on both
sides of the washer.
30, and 31)
• Tighten nut until no end play is detectable while
Tools Required: holding the flange with J 8614-01 (figure 16).
J 35512 Bearing Installer (T, K1 and K2 Models) • No further tightening should be attempted until
J 36614 Bearing Installer (K3 Models) the bearing preload has been checked.
J 36333 Seal Installer Measure (Figure 32)
1. Shim to the pinion gear.
• The shim must be of the proper size, as select • Pinion bearing preload. Use an inch-pound torque
ed previously. wrench (figure 32). The correct preload is 1.7-2.8
2. Bearing onto the pinion gear using J 35512 (T, K1 N-m (15-25 lbs. in.).
and K2 models) or J 36614 (K3 models) (figure 1. Rotate the pinion with the torque wrench and
30). observe the reading.
3. New spacer onto the pinion gear. 2. If the preload torque is below specifications,
4. Bearing into the case. continue torquing the pinion nut in small incre
5. Seal into the case using J 36366 (figure 31). ments. Check the preload after each tightening.
6. Pinion gear, with bearing and spacer, to the case. Each tightening will increase the bearing
1. Thrust washers and side gears into the differential

case.
• If the same gears and washers are being used,
install them on the same side they were
removed from.
2. Pinion gears.
• Position one pinion gear between the side
gears and rotate the gears until the pinion gear
is directly opposite the opening in the case.
• Place the other pinion gear between the side
gears, making sure the hole in both pinion
gears line up.
3. Thrust washers.
• Rotate the pinion gears toward the opening just
enough to permit the sliding in of the thrust wash
ers.
4. Shaft and pin (T, K1 and K2 models) or bolt (K3
models).
5. Ring gear onto the differential case.
6. Bolts. The bolts have left hand threads.
Important
Always install new bolts. Never reuse the old

bolts.
Tighten
• Bolts alternating in progressive steps to 120

N-m (88 lbs. ft.).
7. Side bearings, using J 22761 (T, K1 and K2 mod
els) or J 29710 (K3 models) and J 8092 (figure 33).
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)
preload by several inch pounds. If the bearing

preload is exceeded, the pinion will have to be
rem oved, and a new collapsible spacer
installed.
3. Once the preload has been obtained, rotate the
pinion several times to make sure that the bear
ings have seated. Recheck the preload, and
adjust if necessary.

+ 4- Install or Connect (Figures 1 through 9, and
33)
Tools Required:
J 22761 Side Bearing Installer (T, K1 and K2
Models)
J 29710 Side Bearing Installer (K3 Models)
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 38—Measuring Backlash at the Pinion

Figure 36—Turning the Adjuster Plug (K3 Models) Flange
ADJUSTING BACKLASH • To increase backlash, turn the left sleeve in,

and turn the right sleeve out an identical
Tools Required: amount. To decrease backlash, turn the right
J 8001 Dial Indicator Set sleeve in and turn the left sleeve out an identi
1. Refer to figures 1 through 9 cal amount.
2. Tighten the right sleeve to 140 N-m (100 lbs. ft.) • Changing the sleeves one notch will change
using J 36599 (figure 35). backlash about 0.08 mm (0.003 inch).
3. Tighten the left sleeve (T, K1 and K2 models) or
adjuster plug (K3 models) to 140 N-m (100 lbs. ft.). GEAR TOOTH CONTACT
• Use J 36599 (T, K1 and K2 models) (figure 35). PATTERN CHECK
• Use J 36615 (K3 models) (figure 36). Before final assembly of the differential, a gear tooth
4. Mark the location of the adjusting sleeves in rela
tion to the carrier halves, so the notches in the
adjusting sleeves can be counted when turned.
ously outlined. It is a final check to verify the correct
5. Turn the right sleeve OUT two notches.
6. Turn the left sleeve (T, K1 and K2 models) or
adjuster plug (K3 models) In one notch.
noisy, or have a short life, or both. With a pattern
7. Rotate the pinion several times to seat the bear
check, the best contact between the ring gear and the
ings.
drive pinion for low noise level and long life can be
MEASURING BACKLASH ensured.
1. Install a dial indicator so the button contacts the GEAR TOOTH TERMS
outer edge of the pinion flange. The plunger must The side of the ring gear tooth which curves outward,
be at a right angle to the pinion flange (figure 38).
2. Move the pinion flange through its free play while concave side is the “coast” side (3). The end of the
holding the differential carrier. Record the dial indi tooth nearest center of ring gear is referred to as the
cator reading. “toe” end (2). The end of the tooth farthest away from
3. Divide the dial indicator reading by 2 to obtain the the center is the “heel” end (1). The toe end of the
actual backlash when using this method. Example:
A dial indicator reading of 0.16 mm means that
there is actually 0.08 mm backlash. TEST
4. Follow the steps for adjusting backlash. 1. Wipe oil out of carrier and carefully clean each
• Gear backlash should be between 0.08-0.25 tooth of the ring gear.
mm (0.003-0.010 inch) with a preferred specifi 2. Apply gear marking compound sparingly to all ring
cation of 0.13-0.18 mm (0.005-0.007 inch). gear teeth using a medium stiff brush. When prop
• If the backlash is incorrect, adjust the sleeves erly used, the area of pinion tooth contact will be
as necessary. Always maintain the “one notch” visible when hand load is applied.
preload on the side bearings. Example: If it is 3. Using a torque wrench, apply a load until a torque
necessary to turn the RIGHT sleeve IN one of 62 N-m (45 lbs. ft.) is required to turn the pinion.
notch, the LEFT sleeve must be turned OUT • A test made without loading the gears will not
one notch. give a satisfactory pattern. Turn the companion
rotates one full revolution then reverse the rota
tion so that the ring gear rotates one revolution
in the opposite direction. Excessive turning of
the ring gear is not recommended.
compare with figure 40 through 42.
ADJUSTMENTS AFFECTING TOOTH CONTACT

Two adjustments can be made which will affect the
tooth contact pattern. These are backlash and pinion
depth. The effects of bearing preloads are not easily
seen on hand loaded teeth pattern tests. These adjust
with the backlash and the drive pinion adjustments.
It may be necessary to adjust both pinion depth and
the backlash to obtain the correct pattern.
Pinion depth is adjusted by increasing or decreasing
the shim thickness between the pinion head and the
inner race of the rear bearing. The shim is used in the
differential to compensate for manufacturing tolerances.
Increasing the shim thickness will move the pinion clos-
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
•Apply a bead of sealer (GM P/N 1052942) or

equivalent to one carrier case half sealing surface.
2. Bolts.
Tighten

3. Left seal. Use J 36600 (T, K1 and K2 models) or
J 22833 (K3 models). Drive into place with a soft
faced hammer.
4. Shaft with deflector. Drive in place with a brass
hammer.
5. Bearing to the output shaft. Use J 33842 (figure
43).
6. Output shaft to the carrier.
7. Vent plug. Use a small amount of sealer (GM P/N
1052942) or equivalent on the threads.
Figure 45— Measuring to Calculate Shim Size-Axle
AXLE TUBE ASSEMBLY Shaft
ASSEMBLY
Install or Connect (Figures 1 through 9 and

44)
Tools Required:
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
OUTPUT SHAFT SHIM SELECTION

• Refer to figures 1 through 9.
• It is necessary to select the proper size output
shaft shim if any of the following components were
replaced:
• Shaft.
• Axle tube.
• Output shaft.
• Carrier case.
• Ring and pinion gears.
• Differential case.
• Bearings.
• Carrier connector (T, K1 and K2 models).
Preferred Method:
Tool Required:
J 34672 Depth Gage (or equivalent)
• Refer to figures 45 through 48
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.
++• Install or Connect (Figures 1 through 9)
1. Original shim to the shaft. Use chassis grease to

hold it in place.
2. Assembled axle tube and shaft to the carrier. Use
no sealer at this time.
3. Bolts.
Size-Dimension "B"
$ Tighten
1. Push on the inner end of the shaft, and move the
shaft outboard as far as it will go. The shaft must
be in this position when measuring dimension “A”.
2. Measure dimension “A.” Use J 34672 or equivalent
Measure (Figure 49)
(figure 45 and 47).
• T, K1 and K2: Tube flange machined surface to Tool Required:
inner surface of connector.
J 8001 Dial Indicator (or equivalent)
• K3: Tube flange machined surface to inner sur
• Shaft end play.
face of axle shaft shoulder.
3. Measure dimension “B.” (figure 46 and 48) 1. Install a dial indicator (J 8001) or equivalent on the
axle tube end. The plunger of the indicator must be
• Carrier machined surface to outer surface of
at a right angle to the axle flange (figure 49).
output shaft.
2. Move the shaft back and forth and read the end
4. Subtract dimension “A” from dimension “B.” play. C o rre c t end p lay is 0 .0 3 -0 .5 1 mm
5. The correct shim size will be one size smaller than (0.001-0.020 inch).
the figure obtained in step 5. Examples: 3. If end play is incorrect, install a thicker or thinner
• If the figure obtained in step 5 was 3.53 mm, shim as needed to bring end play into the specified
use a 3.30-mm shim. range.
Install or Connect (Figures 1 through 9)
1. Bolts.
2. Axle tube assembly.
FINAL ASSEMBLY
jjj| Clean (Figures 1 through 9)
• Sealing surfaces of the tube and carrier assembly.

Remove all oil and grease.
1. Shim, as selected previously, to the output shaft.

Use grease to hold it in place.
2. Sleeve.
3. Spring.
4. Shift shaft, spring, shift fork, and clip assembly to
the carrier case.
• Damper spring fits into shift fork indentation.
• Make sure clip is seated in groove of shift shaft. Figure 50—Checking the Shift Mechanism
• Apply a bead of sealer (GM P/N 1052942) or
equivalent to the tube sealing surface. 7. Actuator. Apply sealer (GM P/N 1052942) or equiv
5. Assembled tube to the carrier assembly. alent to the threads.
6. Bolts. 8. Switch. Apply sealer (GM P/N 1052942) or equiva
lent to the threads.
& Tighten 9. Axle lubricant, as specified.
10. Drain and fill plugs with sealing washers
Inspect (Figure 50) Q Tighten
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.
DRIVE AXLE ASSEMBLY

OUTER DEFLECTOR RING ABS SENSOR RING
REPLACEMENT REPLACEMENT
4- + Remove or Disconnect (Figure 53)
Tools Required:
• Clamp the axle shaft in a vise. J-39245-1 Sensor Ring Installer
• Use soft metal or wood to protect the shaft. J-39245-2 Sensor Ring Spacer (T, K1 and K2)
1. Deflector ring from C/V outer race with a brass drift Deflector ring from C/V outer race and discard.
and a hammer (figure 51). Sensor ring with a drift (figure 53).
• Discard deflector ring. +4- Install or Connect
“►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.
B. Using a 3-inch pipe coupling (T, K1 and K2) or

4-inch pipe coupling (K3), M24 x 2.0 nut, and
fabricated sheet metal sleeve, tighten nut until
deflector bottoms against shoulder of C/V outer
race.
OUTER JO IN T SEAL
REPLACEMENT
Remove or Disconnect (Figures 54)
Tools Required:
J 36652 Swage Clamp Tool
1. Large swage ring from the C/V joint, using a chisel
and discard.
Important
• Do not cut through the seal and damage the

sealing surface of C/V outer housing with the
chisel.
2. Small seal-retaining clamp on axle shaft using
J 35910 (figure 54).
• Discard small seal retaining clamp.
A. Separate the joint seal from the C/V joint race
at large diameter and slide the seal away from
joint along the axle shaft.
B. Wipe excess grease from face of C/V inner
race.
C. Spread the ears on the race retaining ring with
J 8059 and remove the C/V joint assembly from
the axle shaft.
3. Seal from the axle shaft.
• Disassemble the joint and flush grease prior to
installing the new seal. Refer to “OUTER JOINT
ASSEMBLY REPLACEMENT.”
Figure 57—Installing Swage Ring
Figure 58—Swage Ring in Proper Alignment

Install or Connect (Figures 55 through 58) C. Slide large diameter of the seal with the large
swage ring in place over the outside of the C/V
1. Small seal-retaining clamp on the neck of the new joint race and locate the seal lip in the housing
seal. Do not crimp. groove.
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).
E. Mount the proper size swage clamp tool in the

vise and proceed as follows:
a. Position the outboard end of the axle
assembly in the tool.
b. Place the top half of the tool on the lower
half of the tool and check for proper align
ment (figure 57 and 58).
c. Insert the bolts and tighten by hand until
snug.
Important
• Make sure the seal, (2) housing, and (3)

swage ring all remain in alignment (figure 57
and 58).
d. Continue to tighten each bolt 180 degrees at
a time alternately until both sides are bot
tomed.
F. Remove the axle assembly from the tool.
Figure 60—Separating Outer Race and Cage
OUTER JO IN T ASSEMBLY
REPLACEMENT
Disassemble (Figures 59 and 60)
*
1. Perform steps 1 through 3 in “OUTER JOINT
SEAL REPLACEMENT.”
2. Use a brass drift and hammer to gently tap on the
C/V joint cage until it is tilted enough to remove the
first chrome alloy ball (figure 59).
3. Tilt the cage in opposite direction to remove oppos
ing ball.
• Repeat this process until all six balls are
removed.
4. Position the cage and the inner race 90 degrees to
the centerline of the outer race and align the (1)
cage windows with the (2) lands of the outer race
(figure 60).
5. Separate the cage and the inner race from the
outer race.
Figure 61—Separating Inner Race and Cage
6. Rotate the inner race 90 degrees to the center line

of the cage with the lands of the inner race aligned
with the windows of the cage (figure 60).
7. Pivot the inner race into the cage window and
remove the inner race.
* Assemble (Figures 59, 60, and 61)
• Apply chassis grease to the ball grooves of the

inner race, and outer race.
1. Inner race to the cage.
A. Rotate (3) inner race 90 degrees to center line

of cage with (1) lands of inner race aligned with
(2) windows of cage (figure 61).
B. Align the (1) cage windows with the (2) lands.
Pivot the cage into position (figure 60).
C. Make sure the retaining ring side of the inner
race faces out.
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
• Be sure that retaining ring side of inner race

faces the axle shaft.
3. Install outer joint seal. Refer to “OUTER JOINT
SEAL REPLACEMENT” in this section.
INNER TRIPOT SEAL

REPLACEMENT
J 8059
+-► Remove or Disconnect (Figures 57, 58, and 62
through 65)
Tools Required:
J 8059 Snap Ring Pliers Figure 63—Installing Spider Assembly
J 36652 Swage Clamp Tool
1. Large swage ring from the in-pot joint, using a chis
el, and discard.
Important
• Do not cut through the seal with the chisel and

damage the sealing surface of the tripot outer
housing.
2. Small seal-retaining clamp from the axle shaft with
a side cutter, and discard.
• Separate seal from the tripot housing at the
large diameter and slide the seal away from the
joint along the axle shaft.
3. Tripot housing from the spider and shaft.
• Spread the spacer ring with J 8059 and slide
the spacer ring and the tripot spider back on
the axle shaft (figure 62).
4. Shaft retaining ring from the groove on the axle
shaft and slide the spider assembly off the shaft. Figure 64— Installing Tripot to Housing
Important
• Handle the tripot spider assembly with care or

the tripot balls and needle rollers may separate
from the spider trunions.
Remove the spacer ring and the seal from the axle
shaft.
Flush grease from the housing.
Small seal-retaining clamp on the neck of the seal.

• Do not crimp.
Slide the seal onto the shaft and position the neck
of the seal in the seal groove on the axle shaft.
•Crimp seal retaining clamp using J 35910 to
Figure 62— Removing Spider Assembly 136 N m (100 lbs. ft.) (figure 56).
7. Slide the tripot housing over the tripot spider

assembly on the shaft (figure 64).
8. Slide the large diameter of the seal with the large
swage ring in place over the outside of the tripot
housing and locate the seal lip in the housing
groove.
9. Position the tripot assembly at the proper vehicle
dimension as shown in figure 65.
Important
The seal must not be dimpled, stretched or out

of shape in any way. If the seal is not shaped
correctly, slide the swage ring off the seal and
onto the housing. Carefully insert a thin, flat,
blunt tool (no sharp edges) between the seal
opening and the housing to release the air.
Shape the seal properly by hand and remove
the tool.
10. Return the swage ring to position on the seal.
3. Spacer ring on the front axle shaft and beyond the
• Select the proper size swage clamp tool
second groove as shown (figure 63).
J 36652.
• Slide the tripot spider assembly against the
11. Mount the swage clamp tool in the vise and pro
spacer ring and the shaft.
ceed as follows:
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 —

Pinion Shaft Shims
(K15-25 Models).................................................................................................................. 0.020-0.024-inch
0.025-0.029-inch
0.030-0.034-inch
0.035-0.039-inch
(K35 Models)....................................................................................................................... 0.508-0.5842 mm
0.6096-0.7112 mm
0.7366-0.8382 mm
0.8386-0.9398 mm
Output Shaft Shims
K15-25 Models............................................................................................ 1.27, 1.78, 2.29, 2.70, 3.30, 3.81 mm
K35 Models................................................................................................. 1.80, 2.30, 2.80, 3.30, 3.80,
4.30, 4.80 mm
PINION PRELOAD AND BACKLASH

Pinion Preload..................................................................................................... 1.7-2.8 N-m (15-25 lbs. in.)
Backlash.............................................................................................................. 0.08-0.25 mm (0.003-0.010-inch)
(Preferred)......................................................................................... .......... 0.13-0.18 mm (0.005-0.007-inch)
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
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)
10. Case Bushing Replacer
(K15-25 Models)
(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
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
19. Pinion Bearing Installer (K15-25 Models) 30. Depth Gage

20. Pinion Bearing Installer (K35 Models) 31. Side Bearing Adjuster Wrench
21. Pinion Seal Installer 32. Dial Indicator Set
22. Axle Seal Installer (K15-25 Models) 33. Clamp Swage Tool Set
23. Axle Seal Installer (K35 Models) 34. Snap Ring Pliers
24. Holding Fixture and Pinion Service Tool 35. Drive Axle Seal Clamp Pliers
25. Dial Indicator Adapter 36. Side Bearing Cup Installer
26. Side Bearing Adjuster Wrench
27. Pinion Depth Setting Gage
28. Dial Indicator
29. Dial Indicator
F6762
NOTES
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
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n?u isbfiifyQ iggft&M
»***• •<
MASTER CYLINDER U N IT REPAIR 5A1-1
SECTION 5A1
MASTER CYLINDER UNIT REPAIR

be used. Fasteners that are not reused and those requiring thread locking compound will be called out.
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
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
CAUTION: If air pressure is used to remove

the secondary piston, place the open end of
the cylinder bore approximately 25 mm (1
inch) from a padded workbench or other sur
face to catch the piston when it comes out if
the bore. Apply low air pressure very careful
ly to ease the piston out of the bore. Never
point the open end of the bore at anyone
when applying air pressure. The piston may
come out of the bore with considerable force
and cause personal injury.
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.
-►+ Install or Connect (Figures 1 through 4, 6,

CAST IRON MASTER CYLINDER
— and 7) ++ Remove or Disconnect (Figures 8 through 10)
• Lubricate the grommets, seals, and cylinder bore
with clean brake fluid. 1. Cover.
1. Spring and spring retainer. 2. Diaphragm.
2. Seals on the secondary piston. 3. Brake fluid from reservoir.
3. Secondary piston. 4. Snap ring.
4. Primary piston assembly. 5. Primary piston assembly.
Figure 6—Installing the Reservoir Figure 8—Cast Iron Master Cylinder Cover
10. Tube seats (if necessary) (figure 10).

• Thread a self-tapping screw into the tube seat
and remove with locking jaw pliers.
Clean
• All metal parts in denatured alcohol.

• All rubber parts in clean brake fluid.
• Stained or discolored cylinder bore with crocus
cloth.
J^ Inspect
• Diaphragm for cuts, cracks, or a swollen condition.

• Cylinder bore for scoring or corrosion.
— If corrosion is present, replace the cylinder.
— Do not attempt to hone the bore.
Figure 9—Cast Iron Master Cylinder Body

Install or Connect (Figures 8, 9 and 11)
• Lubricate seals and cylinder bore with clean brake

fluid.
1. Spring.
2. Primary seal and spring retainer on secondary
piston.
3. Secondary seals on secondary piston.
5. Primary piston assembly.
6. Snap ring.
• The primary piston must be compressed to

install the snap ring.
7. Diaphragm in cover.
8. Cover.
9. Tube seats (if removed).
• Seat the tube seats with a spare brake tube nut
(figure 11).

face to catch the piston when it comes out of
• With the rear port plugged, apply a small

amount of air pressure to the front port.
7. Secondary seals from secondary piston.
8. Spring retainer and primary seal.
9. Spring. Figure 11—Installing the Tube Seats
MASTER CYLINDER U N IT REPAIR 5A1-S
BENDIX MASTER CYLINDER

Remove or Disconnect (Figure 12 and 13)
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.

face to catch the piston when it comes out of
10. Secondary piston assembly.

• With the front port plugged, apply a small
amount of air pressure to the front compensat
ing valve port.
11. Secondary spring.
Ijjp Clean
All metal parts in denatured alcohol.

All rubber parts in clean brake fluid.
A stained or discolored cylinder bore with crocus Figure 13—Bendix Master Cylinder Body
cloth. 4. Primary piston assembly and snap ring.
• The primary piston must be depressed to install
I? Inspect
the snap ring.
Diaphragm for cuts, cracks, or a swollen condition. 5. O-ring and springs.
Cylinder bore for scoring or corrosion. 6. Valve poppets and compensating valve seals.
7. Depress and hold primary piston assembly with
— If corrosion is present, replace the cylinder.
a smooth rounded end tool.
— Do not attempt to hone the bore.
8. Reservoir.
9. Bolts.
Install or Connect (Figure 12 and 13)
$ 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.
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
CONTENTS
SUBJECT PAGE
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
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).
Notice: Do not stake a tab that has previous

ly been staked. The tab may break at a later
time and system failure may occur.
• Assembly can be aided by connecting a

vacuum source to the booster.
12. Grommet and vacuum check valve.
13. Lubricate inside and outside diameters of grommet
and front housing seal with a thin layer of Delco
Silicone Lube (GM P/N 18010909) or equivalent. Diaphragms
15. Silencer and boot. 3. Front housing seal.
4. Scribe a mark on front and rear housings to aid in
Measure assembly.
5. Unlock front and rear housings (figure 1).
Booster pushrod length. Refer to “GAGING PRO
CEDURE.” A. Set booster in disassembly tool J 23456.
B. Tighten fixture hand screw just enough to allow
DUAL DIAPHRAGM housing to rotate.
C. Apply force in a counterclockwise direction to
Remove or Disconnect (Figures 1, 7 through unlock housings.
D. Back off fixture hand screw and housings will
11)
separate.
Tool Required:
J 23456 Power Brake Booster Disassembly and 6. Return spring and power piston group (figure 10).
Reassembly Tool 7. Primary piston bearing from rear housing.
8. Piston rod, reaction body retainer, and reaction
retainer.
1. Boot and silencer.
9. Power head silencer.
2. Vacuum check valve and grommet.
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
All parts for corrosion, nicks, cracks, cuts, scoring,

distortion, or excessive wear. Replace as needed.
Use crocus cloth to polish away minor corrosion
from the housings or diaphragm support.
Clean
All parts in clean denatured alcohol.

Do not immerse the power piston assembly in alco
hol. Wipe clean with an alcohol dampened cloth.
Dry all parts with dry, unlubricated, compressed air.
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.
Figure 12— Installing the Retainer in the Power Figure 14—Assembling the Housing Divider
Piston
16. Primary diaphragm into the primary support plate

and Support
(figure 15).
10. Lubricate inside diameter of secondary diaphragm • Fold primary diaphragm up and away from pri
lip with a thin layer of Delco Silicone Lube (GM P/N mary support plate.
18010909) or equivalent. 17. Primary diaphragm and support plate over power
11. Secondary diaphragm and support plate over pow piston assembly.
er piston assembly and pushrod (figure 13). • Unfold primary diaphragm back in position and
• Use J 28458 as a guide to protect power pis pull outside edge of diaphragm over formed
ton. flange of housing divider.
12. Secondary piston bearing into housing divider with • Make sure the beads on secondary diaphragm
flat surface of the bearing on the same side as six are seated evenly around the complete circum
raised lugs on divider. ference.
13. Lubricate inside diameter of secondary piston bear 18. New diaphragm retainer and seat using J 28458
ing with a thin layer of Delco Silicone Lube (GM (figure 16).
P/N 18010909) or equivalent. • Do not reuse original retainer.
14. Secondary piston bearing and housing divider over 19. Silencer, reaction retainer, reaction body retainer,
the power piston assembly (figure 14). and piston rod .
• Use J 28458 as a guide. 20. Lubricate inside and outside diameters of primary
15. Lubricate inside diameter of primary diaphragm lip piston bearing with Delco Silicone Lube (GM P/N
with a thin layer of Delco Silicone Lube (GM P/N 18010909) or equivalent.
18010909) or equivalent. 21. Primary piston bearing in rear housing.
Figure 16— installing the Diaphragm Retainer Figure 18—Gaging the Piston Rod
E. Back off the fixture screw.

F. Stake housing at two tabs 180 degrees apart
(figure 17).
Notice: Do not stake a tab that has previous

ly been staked. The tab may break at a later
time and system failure may occur.
• Assembly can be aided by connecting a vacu

um source to the booster.
25. Lubricate inside and outside diameters of grommet
and front housing seal with a thin layer of Delco
Silicone Lube (GM P/N 18010909) or equivalent.
26. Grommet and vacuum check valve.
28. Silencer and boot.
Figure 17— Staking the Housing Tabs GAGING PROCEDURE

Tool Required:
22. Power piston group in rear housing.
J 37839 Push Rod Height Gage
23. Return spring.
24. Lock front and rear housings using the following • Gage the piston rod using J 37839 (figure 18).
steps:
A. Apply 85.0 kPa (25 In. Hg.) vacuum or maxi
A. Set assembled rear housing group in assembly mum engine vacuum to the booster.
tool J 23456. B. Check the maximum and minimum rod length.
B. Align the scribe marks on housings.
• If the piston rod is not within limits, obtain a
C. Tighten the fixture hand screw just enough to
service adjustable piston rod and adjust the
allow for housing rotation (figure 1).
rod to the correct measurement.
D. Apply force in a clockwise direction to lock the
front and rear housings.
SPECIAL TOOLS
1. POWER BRAKE PUSH ROD HEIGHT GAGE

2. POWER BRAKE BOOSTER DISASSEMBLY AND
REASSEMBLY TOOL
3. POWER PISTON SEAL PROTECTOR
4. AIR VALVE PUSH ROD RETAINER INSTALLER
V3763
HYDRAULIC BOOSTER 5D3-1
SECTION 5D3
HYDRAULIC BOOSTER
CONTENTS
SUBJECT PAGE
Unit Repair....................................................................................................................................................................5D3-1
Booster Assembly...................................................................................................................................................5D3-1
Gaging Procedure....................................................................................................................................................5D3-4
Power Steering Pump............................................................................................................................................ 5D3-4
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.
|<-+| Remove or Disconnect (Figures 1 through 7)
Tool Required:
J 26889 Accumulator Piston Compressor
1. Place J 26889 over end of accumulator and install

a nut on stud (figure 4).
2. Depress accumulator with a C-clamp.
3. Insert a punch in hole on housing. Figure 1—Hydraulic Booster Accumulator
5D3-2 HYDRAULIC BOOSTER
Figure 5—Removing the Plug and Spring
Rod Figure 6—Removing the Accumulator Valve
Figure 4—Removing the Accumulator Figure 7—Removing the Tube Seat

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
• All parts with power steering fluid.
L1 Inspect
• Spool valve and spool valve bore for corrosion,

nicks, and scoring.
— Discoloration of the spool or bore is not harmful
and is no cause for replacement.
J 25083
• Housing and cover sealing surface for corrosion or J 24551- A
nicks.
• Tube seat in the housing for burrs, nicks, or corro
sion. Replace if needed (figures 7 and 8).
• If damage to the booster is found, replace the com Figure 9—Installing the Piston Assembly
plete booster.
Install or Connect (Figures 1 through 3, 8, 9,

and 10)
Tools Required:
J 26889 Accumulator Piston Compressor
J 24551-A Seal Protector
J 25083 Seal Protector
1. Lubricate all seals and metal friction points with

2. Seal and return line fitting.
3. Accumulator valve.
4. Spool valve.
5. Seal and piston assembly (figure 9).
• Lubricate J 24551 -A or J 25083 with clean pow
er steering fluid.
• Use the proper tool to install the piston assem
bly.
6. Seal on piston assembly.

7. Seal on housing.
8. Cover on housing. J 37839
9. Bolts.
$ Tighten

10. Bracket and nut.
a Tighten
• Nut to 149 N-m (110 lbs. ft.).

11. Boot.
12. Output pushrod assembly (figure 10).
• Retainer, piston return spring, baffle, and output
pushrod using J 24551 -A or J 25083.
13. Retainer. Figure 11—Gaging the Piston Rod
14. Plug and spring assembly (figure 5).
A. O-ring seal on plug.
B. Spring, O-ring seal, and plug.
GAGING PROCEDURE
15. Retainer. Tool Required:
16. Accumulator assembly. J 37839 Push Rod Height Gage
A. O-ring seal on accumulator. 1. Gage the piston rod using J 37839 (figure 11).
B. O-ring seal and accumulator using J 26889 and • Check the maximum and minimum rod length.
a C-clamp (figure 4). 2. If the piston rod is not within limits, obtain a service
C. Depress the accumulator adjustable piston rod and adjust the rod to the cor
D. Retainer. rect measurement.
E. Release C-clamp.
F. Remove J 26889. POWER STEERING PUMP
17. Jam nut from repair kit on pedal rod. For power steering pump unit repair, refer to SEC-
18. Eyelet on pedal rod. TION 3B1B.
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
1. POWER BRAKE PUSH ROD HEIGHT GAGE

2. PISTON SEAL PROTECTOR
3. PISTON SEAL PROTECTOR
4. ACCUMULATOR PISTON COMPRESSOR
5. VALVE CONNECTOR SEAL INSTALLER
F9233
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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GENERAL ENGINE MECHANICAL 6A-1
SECTION 6A
GENERAL ENGINE MECHANICAL

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.
CYLINDER BORES, PISTONS, RINGS, AND

CONNECTING RODS
MEASURING CYLINDER BORE 4. Fine vertical scratches made by ring ends will not,
by themselves, cause excessive oil consumption;
TAPER AND OUT-OF-ROUND therefore, honing to remove them is unnecessary.
(ALL ENGINES) 5. If the bore is glazed but otherwise serviceable,
break the glaze lightly with a hone and replace the
Tool Required:
piston rings. Refer to “Honing.”
J 8087 Cylinder Bore Gage (or equivalent)
• If one or more cylinder bores are rough, scored or • Make sure the honing stones are clean, sharp,
worn beyond limits, it will be necessary to smooth and straight. Move the hone slowly up and
or true up such bores to fit new pistons. down to produce a 45 degree cross-hatch pat
• No attempt should be made to cut down oversize tern. Clean the bore thoroughly with soap and
pistons to fit cylinder bores as this will destroy the water. Dry and rub in clean engine oil, then
surface treatment and affect the weight. The smal remeasure.
lest possible oversize service pistons should be 6. If honing is not required, the cylinder bores should
used and the cylinder bores should be honed to be cleaned with a hot water and detergent wash.
size for proper clearances. Apply clean engine oil to the bore after cleaning.
1. Refer to “Specifications” in the proper section for
tolerances.
2. Set the gage so the thrust pin must be forced in
about 7 mm (1/4 inch) to enter the gage in the
cylinder bore.
3. Center the gage in the cylinder and turn the dial to
“ 0.”
4. Carefully work the gage up and down the cylinder
to determine taper and turn it to different points
around the cylinder w all to d eterm ine the
out-of-round condition (figure 1). Measure the bore
both parallel to and at right angles to the engine
centerline. Measure at the top, middle, and bottom
of the bore and note the readings.
5. Recondition the cylinder bore as necessary. Refer
to “Cylinder Bore Reconditioning.”
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
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.
NOTICE: Handle the pistons with care and do

not attempt to force them through the cylin
der until the cylinder has been honed to the
correct size. The piston can be distorted
through careless handling.
4. When finish honing a cylinder bore to fit a piston,

move the hone up and down at a sufficient speed
to obtain very fine uniform surface finish marks in a
cross-hatch pattern at the specified angle.
• 2.2L: 45 degrees
• All others: 45 to 65 degrees
5. The finish marks should be clean but not sharp,
free from imbedded particles and torn or folded
metal.
6. By measuring the piston to be installed at the siz
ing point specified in the proper section, and
adding the average of the clearance specification,
the finish hone cylinder measurement can be deter
mined. It is important that both the block and piston
be measured at normal room temperature. Figure 4—-Piston Rings
7. It is of the greatest importance that refinished cylin
der bores are trued up to have less than the speci
fied out-of-round or taper. Each bore must be final
honed to remove all stone or cutter marks and
provide a smooth surface.
8. Refer to “Specifications” in the proper section for
piston to bore clearance tolerances.
9. After final honing and before the piston is checked
for fit, clean the bores with hot water and deter
gent. Scrub with a stiff bristle brush and rinse thor
oughly with hot water. It is essential that a good
cleaning operation be performed. If any of the
abrasive material is allowed to remain in the cylin
der bores, it will wear the new rings, cylinder bores,
and bearings lubricated by the contaminated oil.
After washing, the dry bore should be brushed
clean with a power-driven fiber brush.
10. Permanently mark the piston for the cylinder to
which it has been fitted.
11. Apply clean engine oil to each bore to prevent rust
ing.
Figure 5— Removing the Piston Rings
PISTON AND CONNECTING
ROD ASSEMBLIES
DISASSEMBLY Py| Clean
Disassemble (Figures 4, 5, and 6) • Piston.

— Remove all varnish and carbon deposits. DO
Tools Required:
NOT USE A WIRE BRUSH.
J 24086-B Piston Pin Remover and Installer
— Remove the carbon from the ring grooves. Use
1. Piston rings. In most cases the rings should be
a ring groove cleaning tool.
discarded and replaced with new ones at assem
— Oil-control ring groove holes.
bly.
2. Connecting rod bearing inserts. If the inserts are to
be reused, place them in a rack so they may be L* Inspect
reinstalled in their original connecting rod and cap.
3. Piston pin (figure 6). • Piston pin bore in the piston and connecting rod.
A. Place the piston/connecting rod on support fix Check for scuffing, burrs, etc.
ture J 24086-20. Make sure the connecting rod • Piston for scratches, wear, etc.
is fully supported. • Connecting rod for cracks, nicks, etc. If a suitable
B. Place remover J 24086-8 on the support fixture. jig is available, check the connecting rod for a bent
C. Press out the piston pin. or twisted condition.
24086 - 8
J 24086
Figure 7—Measuring Piston Pin Diameter

Figure 6— Removing the Piston Pin
• 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.
MEASURING PISTON PIN TO PISTON CLEARANCE
Measure (Figures 7 and 8)
1. Piston pin diameter (figure 7). Check against

“Specifications.”
2. Piston pin to piston clearance.
A. Measure the piston pin hole diameter (figure 8).
B. Subtract the piston pin diameter from the piston
pin hole diameter to obtain the clearance. Figure 8— Piston Pin Hole Diameter
C. Replace the piston and piston pin if the clear
ance exceeds specifications. The piston and
piston pin are a matched set and not available
separately.
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.
M Measure (Figures 9 and 10)
A. Cylinder bore diameter. Use a telescoping bore

gage, located 65 mm (2 1/2 inches) below the
top of the cylinder bore (figure 9).
B. Piston diameter. Measure the piston skirt at a
right angle to the piston pin, at the centerline of Figure 9— Measuring Cylinder Bore Diameter
the piston pin (figure 10).
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.
I f Inspect (Figure 13)
Ring fit as follows:

1. Fit each compression ring to the piston on
which it is going to be used.
2. Slip the outer surface of the top and second
compression ring into the respective piston ring
groove (figure 13), to make sure the ring is free.
If binding occurs at any point, the cause should
be determined. If binding is caused by the ring
groove, correct it by dressing the groove with a
fine cut file. If the binding is caused by a distort
ed ring, try a new ring.
Assemble (Figures 4 and 5)

*
• All compression rings are marked on the upper
side of the ring. When installing the compression
rings, make sure the MARKED SIDE IS TOWARD Figure 14— Measuring Ring Clearance
THE TOP OF THE PISTON. groove, correct it by dressing the groove with a
•T h e oil control rings are 3-piece types, consisting fine cut file. If binding is caused by a distorted
of two rails and an expander. ring, try a new ring.
1. Expander. — Ring gaps must be 180 degrees apart.
— Rail gaps must be 180 degrees apart.
2. Lower rail.
3. Upper rail.
Measure (Figure 14)
4. Upper compression ring.
5. Lower compression ring.
Ring clearance. Use a feeler gage as shown in
• Flex all rings to make sure they are free. If figure 14. Compare with “Specifications” in the
binding occurs at any point the cause should be proper section.
determined. If binding is caused by the ring
CAMSHAFT BEARINGS
CAMSHAFT BEARING Clean
REPLACEMENT (2.2L ENGINES) • Camshaft bearing bores in the block.

Refer to the proper section. + 4<r Assemble (Figures 15 and 16)
CAMSHAFT BEARING Tool Required:

J 33049 Camshaft Bearing Remover and
REPLACEMENT (ALL EXCEPT Installer
2.2L ENGINES) • The outer camshaft bearings must be installed first.
These bearings serve as guides for the pilot, and
L* Inspect help center the inner bearings during the installa
tion process.
Camshaft bearings for scratches, pits, or loose fit in • Make sure to fit the correct cam bearing into the
their bores. Replace the camshaft bearings if nec bore. The cam bearing bores vary in size.
essary. .Outer camshaft bearings. Drive the bearings into
place using J 33049 (figure 15).
Disassemble (Figures 15)
* Important
Tool Required: • Make sure the camshaft bearing hole (or holes)
J 33049 Camshaft Bearing Remover and align with the oil hole (or holes) in the block. On
Installer some engines, the oil holes may be difficult to
1. Rear camshaft plug. see. If so, use a piece of 2 mm (3/32 inch) rod
2. All camshaft bearings. Use J 33049 (figure 15). to check alignment (figure 16). The rod should
be 762 mm (30 inches) long.
A. Insert the tool with the correct collet into the 2. Inner camshaft bearing. Use tool J 33049 (figure
camshaft bearing you want to replace. 15).
B. Turn the tool until the collet has tightened in the A. Assemble the tool with the pilot engaged in the
bearing. front bearing and the pilot flange against the
C. Push the center cone against the block and into front face of the block.
the first bearing bore to center the tool. B. Slide the puller screw (with nut and washer)
D. Drive the bearing from the block. through the pilot.
E. Repeat this procedure to remove the remaining C. Place the new bearing on the bearing tool. Hold
inner camshaft bearings. Note that the rear the bearing tool and bearing against the bearing
bearing must be removed from the front of the bore. Align the bearing oil hole with the oil hole
block and the front bearing should be removed in the block.
from the rear. This allows the tool to remain D. Thread the puller screw into the bearing tool
centered. enough to hold the tool and bearing in place.
E. Holding the puller screw with a wrench, turn the
nut with a second wrench to pull the camshaft
bearing into place.
F. Remove the puller screw, pilot, and bearing
tool.
Figure 15— Removing or Installing Camshaft Figure 16—Checking Camshaft Bearing Oil Hole
Bearings Alignment (Typical)
Important 3. Camshaft rear plug or cap.

A. Coat a new camshaft plug with sealer (Loctite
• Make sure the camshaft bearing hole (or #592 or equivalent).
holes) align with the oil hole (or holes) in the B. Install the plug flush to 0.80 mm (1/32 inch)
block. If it is difficult to see the alignment, deep.
use a piece of brass rod as described in C. Install the cap while the RTV is still wet.
step 1. D. Install the retaining bolts and tighten.
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.
CYLINDER HEAD
DISASSEMBLY Valve stems and heads on a wire wheel.
Carbon and old gasket from the cylinder head gas
Disassemble ket surface.
• Valves and components. Refer to the proper sec J? Inspect

tion.
• Cylinder head for cracks in the exhaust ports, com
CLEANING AND INSPECTION bustion chambers, or external cracks to the coolant
p| Clean (Figures 18 and 19) chamber. Gasket surfaces should be free of dam
age.
Tools Required: • Valves for burning, pitting, or warpage. Grind or
J 8089 Wire Brush replace as needed. Refer to “Valve Grinding.”
J 8101 Valve Guide Cleaning Tool Check the valve stems for scoring or excessive
• Carbon from the combustion chambers, using wear. Stems must not be bent.
J 8089 (figure 18). • Rocker arm studs (if used) for wear, damage, or
•Valve guides, using J 8101 (figure 19). improper fit.
• Valve seats for pitting or other damage. Grind or
reface as needed.
• Rotators (if used). The rotators should rotate
smoothly without binding.
tjjj Measure (Figures 20 through 22)
Tools Required:
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)
Figure 20— Measuring Stem to Bore Clearance

(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.
VALVE SEAT GRINDING

Reconditioning the valve seats is very important,
because the seating of the valves must be perfect for
the engine to deliver the power and performance it was
designed to produce.
Another important factor is the cooling of the valve
head. Good contact between each valve and its seat
ensures that heat will be carried away properly.
Several different types of equipment are available for
resurfacing valve seats. Carefully follow the recommen
dations of the manufacturer of the equipment being
used to attain proper results.
Regardless of what type of equipment is used, it is
essential that valve guide bores be free from carbon or
dirt to ensure proper centering of the pilot in the guide.
Refer to "Specifications" in the proper section for valve
seat angle specifications.
Figure 22— Measuring Valve Spring Length
B. Locate the indicator so movement of the valve

stem from side to side (crosswise to the head)
will cause a direct movement of the indicator
stem. The indicator stem must contact the side of
the valve stem just above the valve guide bore.
C. Drop the valve head about 1.6 mm (1/16 inch)
off the valve seat.
D. Move the stem of the valve from side to side
using light pressure to obtain a clearance read
ing. If clearance exceeds specifications, it will
be necessary to ream the valve guide bores for
oversize valves as outlined later.
• Valve spring tension, using J 9666 or equivalent
(figure 21).
— Compress the springs, with dampers removed,
to the specified height and check against the
specifications chart. Springs should be replaced
if not within 44 N (10 lbs.) of the specified load.
• Valve spring length (figure 22). Replace the spring
if the length is not as specified.
NOTICE: Valve seats on 5.0L (exhaust only),

and 5.7L L.D.(exhaust only) are induction
hardened. The 5.7L H.D. and the 7.4L engines
use hardened seat inserts (exhaust only).
Excessive removal of stock may result in
damage to the valve seats.
REAMING VALVE GUIDES

The valve guides used in engines covered by this
manual are simply holes bored into the cylinder head
except on the 5.7L H.D. and 7.4L engines. The 5.7L
H.D. (exhaust valve only) and 7.4L engines (intake and
exhaust valves) use separate pressed-in valve guides
and are servicable. The valve guides used in all other
engines covered by this manual not replaceable.
If the valve stem to bore clearance as measured pre
viously is excessive, the valve guides should be
reamed and a valve with an oversize stem installed.
Available oversize valves are as follows. Nominal
dimensions are given.
• 2.2L:
— Intake: 0.08 mm (0.003 inch), 0.13 mm (0.005
inch). — These reamers (except J 6621) also available
— Exhaust: 0.08 mm (0.003 inch). in Reamer Set J 5830-02.
• 4.3L H.D., 5.7L H.D.: • 7.4L engines:
— Intake: 0.08 mm (0.003 inch), 0.38 mm (0.015 — J 7049-1: 0.08 mm (0.003 inch) oversize.
inch), 0.76 mm (0.030 inch). — J 7049-2: 0.38 mm (0.015 inch) oversize.
— Exhaust: 0.08 mm (0.003 inch), 0.38 mm (0.015 — J 7049-3: 0.76 mm (0.030 inch) oversize.
inch). — These reamers also available in Reamer Set
Select a reamer that will provide a straight, clean J 7049.
bore through the guide’s entire length (figure 24).
Reamer availability is as follows. Sizes given are ASSEMBLY
nominal.
• All engines except 7.4L: Assemble
— J 5830-1: 0.08 mm (0.003 inch) oversize.
— J 6621: 0.13 mm (0.005 inch) oversize. • Valves and components. Refer to the proper sec
— J 5830-2: 0.38 mm (0.015 inch) oversize. tion.
— J 5830-3: 0.76 mm (0.030 inch) oversize.
MEASURING MAIN BEARING CLEARANCE

Main bearings are of the precision insert type and do b. Subtract journal diameter from bearing inside
not use shims for adjustment. If clearances are exces diameter to obtain bearing clearance. Refer to
sive, new upper and lower bearing inserts will be “Engine specifications” in the applicable section
required. Service bearings are available in standard for proper clearance. Replace the crankshaft if
size and 0.001 inch, 0.002 inch, 0.010 inch, and 0.020 necessary.
inch undersize.
Selective fitting of main bearing inserts is necessary • Crankshaft run-out (figure 26).
in production to obtain close tolerances. For this rea
A. Mount the crankshaft in V-blocks at main jour
son, you may find one-half of a standard insert with
nals 1 and 5.
one-half of a 0.001 inch undersize insert that will
B. Use a dial indicator as shown.
decrease the clearance 0.0005 inch from using a full
standard bearing. C. If the main journals are misaligned, the crank
To determine the correct replacement insert size, the shaft is bent and must be replaced, along with
bearing clearance must be measured accurately. Either the main bearings.
of the following two methods may be used, however,
the micrometer method gives more reliable results and Measure (Figures 27 and 28)
is preferred.
Measure (Figure 25) Plastic Gage Method

%
1. The flattened gaging plastic will adhere to either
Micrometer Method the bearing insert or journal.
1. The crankshaft journal diameter with a micrometer 2. On the edge of the gaging plastic envelope there is
in several places, approximately 90 degrees aprart, a graduated scale. Without removing the gaging
and average the measurements (figure 25). plastic, measure its compressed width (at the wid
2. Compute taper and runout, refer to “Engine Speci est point) with the graduations on the gaging
fications” in the applicable section for allowable plastic envelope (figure 28).
limits. 3. If the flattened gaging plastic tapers toward the
3. Bearing insert I.D. with an inside micrometer. middle or ends, there is a difference in clearance
— Use new inserts if the inserts are being indicating taper, low spot or other irregularity of the
replaced. bearing or journal.
a. Install bearing inserts. 4. Normally main bearing journals wear evenly and
are not out-of-round. However, if a bearing is being
fitted to an out-of-round (0.001 inch maximum)
journal, be sure to fit to the maximum diameter of
•Tighten main bearing cap bolts to 110 N-m
the journal. If the bearing is fitted to the minimum
(81 lbs. ft.).
a. Inside diameter with an inside micrometer. d ia m e te r and th e jo u rn a l is e x c e s s iv e ly
Place the micrometer at 90 degrees to the split out-of-round, interference between the bearing and
line of the bearing. the journal will result in rapid bearing failure.
Figure 25— Measuring the Crankshaft Journals Figure 26—Checking Crankshaft Run-Out
Figure 28— Measuring the Gauging Plastic

Bearing Journal
NOTICE: B earing inserts m ust not be
5. If the bearing clearance is within specifications, the shimmed, scraped or filed. Do not touch the
bearing is satisfactory. If the clearance is not within bearing surface of the insert with bare fin
specifications, replace the bearing. Always replace gers. Skin oil and acids will etch the bearing
both upper and lower inserts as a unit. surface.
6. A standard 0.001 inch or 0.002 inch undersize 7. Remove the flattened gaging plastic.
bearing may produce the proper clearance. If not, it 8. Perform the preceding steps on the remaining main
will be necessary to replace the crankshaft. bearings.
MEASURING CONNECTING ROD BEARING

CLEARANCE
Connecting rod bearings are of the precision insert 3. Bearing insert I.D. with an inside micrometer.
type and do not use shims for adjustment. If clearances
— Use new inserts if the inserts are being
are excessive, new upper and lower bearing inserts will
replaced.
be required. Service bearings are available in standard
size and 0.001 inch, 0.002 inch, 0.010 inch, and 0.020 a. Install bearing inserts.
inch undersize.
Selective fitting of connecting rod bearing inserts is
Tighten
necessary in production to obtain close tolerances. For
this reason, you may find one-half of a standard insert
with one-half of a 0.001 inch undersize insert that will • Tighten connecting rod nuts to 27 N-m (20
decrease the clearance 0.0005 inch from using a full lbs. ft.) plus 70 degrees.
standard bearing. a. Inside diameter with an inside micrometer.
To determine the correct replacement insert size, the
Place micrometer at 90 degrees to the split line
bearing clearance must be measured accurately. Either
of the bearing.
of the following two methods may be used, however,
b. Subtract journal diameter from bearing inside
the micrometer method gives more reliable results and
diameter to obtain bearing clearance. Refer to
is preferred.
“Engine specifications” in the applicable section
Measure (Figure 25) for proper clearance. Replace the connecting
rod if necessary.
Micrometer Method
| Clean
1. The crankshaft journal diameter with a micrometer
in several places, approximately 90 degrees aprart,
and average the measurements (figure 25). All oil from the crankshaft journal and the connect
2. Compute taper and runout, refer to “Engine Speci ing rod bearing inserts.
fications” in the applicable section for allowable
limits.
|j| Measure (Figure 29 and 30)
Plastic Gage Method

Connecting Rod Journal
• Refer to the proper section for additional informa

tion on connecting rod bearing sizing.
1. Connecting rod with the upper connecting rod bear
ing insert to the crankshaft journal.
2. A piece of gaging plastic the length of the bearing
(parallel to the crankshaft) on the journal (figure
29). The gaging plastic should be positioned in the
middle of the upper and lower bearing insert (Bear
ings are eccentric and false readings could occur if
placed elsewhere).
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.
• Nuts to "Specifications.” Refer to the proper

section.
Important
The gaging plastic will be found sticking to either

the journal or lower connecting rod bearing insert. Figure 30— Measuring the Gaging Plastic on the
Do not remove it at this time. Connecting Rod Journal
* 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.
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.
CAUTION: Wear safety glasses to avoid eye

damage.
1. Determine size, pitch, and depth of damaged

thread. If necessary, adjust stop collars on cutting
tool and tap to required depth.
Important
• Refer to the kit manufacturer’s instructions

regarding the size of drill and tap to be used.
2. Drill out damaged thread. Clean out chips.
3. Tap hole. Lubricate tap with light engine oil. Clean
the thread (figure 31).
Important
• Avoid buildup of chips. Back out the tap every

few turns and remove chips.
4. Thread the thread insert onto the mandrel of the
installer (figure 32). Engage the tang of the insert
onto the end of the mandrel.
5. Lubricate the insert with light engine oil (except
when installing in aluminum) and install.
Important
• When correctly installed, the insert should be

flush to one turn below the surface.
6. If the tang of the insert does not break off when
backing out the installer, break the tang off with a Figure 32—Installing Insert
drift.
SPECIAL TOOLS
3- | o e J 6 0 9 8 " 0 1 7- J 8001
1. CYLINDER BORE GAGE

2. PISTON PIN REPLACER SET
3. CAMSHAFT BEARING REPLACER
4. HYDRAULIC LIFTER LEAKDOWN TESTER
5. WIRE BRUSH
6. VALVE GUIDE CLEANING TOOL
7. DIAL INDICATOR
8. VALVE SPRING TESTER
9. VALVE GUIDE REAMER SET (ALL ENGINES EXC 7.4L) CONSISTS OF:
—J 5830-1: 0.08mm (0.003-INCH) OVERSIZE
10. VALVE GUIDE REAMER SET (7.4L ENGINES) CONSISTS OF:
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
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
Figure 1—Cylinder Head, Manifolds, and Components

4 .3 L V 6 (V IN Z) 6A3B-5
20. Valve Stem Key 163. Bolt 700. Rocker Arm

21. Inlet Valve Spring Cap 164. Coolant Outlet Cover Bolt
22. Valve Stem Oil Shield 165. Coolant Outlet Gasket 701. Rocker Arm Cover
23. Valve Stem Oil Seal (O-Ring) 166. Thermostat 702. Rocker Arm
24. Inlet Valve Stem Seal 167. Vacuum Fitting Cover Gasket
26. Valve Spring with Damper 168. Engine Coolant 704. Crankcase Vent
27. Inlet Valve Temperature Sensor Tube Grommet
28. Exhaust Valve Rotator 169. Bolt 705. Crankcase Vent
29. Exhaust Valve 170. Intake Manifold Valve Grommet
40. Lifter Restrictor Retainer Bolt 171. Oil Pressure Sensor
41. Lifter Restrictor Retainer 172. Oil Pressure Fitting
42. Rocker Arm Nut 173. E.G.R. Valve Gasket
43. Rocker Arm Ball 174. E.G.R. Valve V" > ’ '
44. Rocker Arm 175. Bolt
45. Push Rod 176. Intake Manifold Gasket
46. Valve Lifter Guide (Restrictor) 177. Nut
47. Lifter 178. Power Booster
48. Flat Washer Vacuum Pipe
50. Cylinder Head Bolt 179. Exhaust Manifold
51. Spark Plug 180. Power Booster Vacuum
52. Coolant Temperature Sensor Pipe Fitting
53. Drain Plug 181. Plua
54. Cylinder Head Gasket 182. Coolant Temperature Sensor
60. Heat Shield 183. Crankcase Ventilation Valve
61. Washer 184. Oil Filler Cap
62. Exhaust Manifold Lock 185. Oil Filler Tube
63. Bolt/Stud 186. Bolt
162. Stud V1199
Figure 2—Cylinder Head, Manifolds, and Components -Legend

6A3B-6 4.3L V 6 (VIN Z)
Figure 3—Cylinder Block and Components

4.3L V6 (VIN Z) 6A3B-7
31. BOLT, OIL PUMP 145. KEY, WOODRUFF

56. PUMP, OIL 148. CAMSHAFT
57. SCREEN, OIL PUMP 149. GASKET, COOLANT PUMP
58. SHAFT, OIL PUMP DRIVE 150. BOLT/STUD, COOLANT PUMP
59. PIN 151. PUMP, COOLANT
60. SPRING, OIL PRESSURE RELIEF 152. SPROCKET, CRANKSHAFT
61. VALVE, OIL PRESSURE REGULATOR 153. BOLT
62. PLUG 154. SPROCKET, CAMSHAFT
64. RETAINER, OIL PUMP DRIVE SHAFT 155. CHAIN, TIMING
65. COVER, OIL PUMP 156. BEARING, CAMSHAFT
70. GASKET, OIL PAN 158. TUBE, OIL LEVEL INDICATOR
71. REINFORCEMENT, OIL PAN 159. INDICATOR, OIL LEVEL
72. PAN, OIL 160. BOLT
80. SCREW, SEAL RETAINER 161. PIN, PISTON
81. NUT, SEAL RETAINER 187. BOLT, BALANCE SHAFT DRIVEN GEAR
82. RETAINER, SEAL 188. GEAR, BALANCE SHAFT DRIVEN
83. STUD, SEAL RETAINER 189. GEAR, BALANCE SHAFT DRIVE
84. GASKET, SEAL RETAINER 190. RETAINER, BALANCE SHAFT
87. RETAINER, CAMSHAFT 191. SHAFT, ENGINE BALANCE
88. SCREW, CAMSHAFT RETAINER 192. SCREW, BALANCE SHAFT RETAINER
91. GASKET 193. BEARING, BALANCE SHAFT REAR
92. ADAPTER 194. PLUG, CUP
93. BOLT 195. NUT, CAMSHAFT SPROCKET
94. FITTING 196. STUD, CAMSHAFT SPROCKET
100. CAP, MAIN BEARING 207. PLUG, HEX
101. CRANKSHAFT 208. SEAL, BALANCE SHAFT REAR BEARING PLUG
102. FILTER, OIL 209. PLUG, EXPANSION CUP
103. RINGS, PISTON 210. PLUG, SQUARE
104. PISTON 211. PIN, DOWEL
105. ROD, CONNECTING 212. PLUG, HEX
106. BEARING, CONNECTING ROD 213. PLUG, KNOCK SENSOR HOLE
107. CAP, CONNECTING ROD BEARING 214. PLUG, OIL PRESSURE
108. NUT, CONNECTING ROD BOLT 215. VALVE, OIL FILTER BYPASS
114. BLOCK, ENGINE 216. PLUG, OIL GALLERY
128. STUD, OIL PAN 217. GEAR, FLYWHEEL RING
129. BOLT, OIL PAN 218. PIN, OIL PRESSURE RELIEF VALVE SPRING
130. CLIP 219. PLUG, OIL PAN DRAIN
132. BOLT, MAIN BEARING CAP 220. GASKET, OIL PAN DRAIN PLUG
133. PIN, GROOVE 221. PIN
134. FLYWHEEL 222. NUT, HEX
135. BOLT, FLYWHEEL 223. NUT, HEX
136. INSERT, LOWER MAIN BEARING 224. BEARING, BALANCE SHAFT FRONT
137. SEAL, CRANKSHAFT FRONT OIL 225. PLUG, OIL PRESSURE
138. DAMPER, CRANKSHAFT TORSIONAL 226. PLUG, HEX
139. PIN, GROOVE 227. SEAL, OIL LEVEL INDICATOR TUBE
141. BOLT 228. FITTING, OIL PRESSURE GAGE
142. COVER, FRONT 229. SENSOR, OIL PRESSURE GAGE
143. GASKET, FRONT COVER 230. SENSOR, KNOCK
144. INSERT, UPPER MAIN BEARING
V3703
Figure 4—Cylinder Block and Components - Legend

6A3B-8 4.3L V6 (VIN Z)
Figure 5—Engine Lubrication Diagram
DISASSEMBLY OF THE ENGINE

TOOLS AND SHOP EQUIPMENT ACCESSORY REMOVAL
A clean well-lit work area should be available. Other The various procedures in this manual assume that
necessary equipment includes: a suitable parts cleaning the engine accessories have been removed. These
tank, compressed air supply, trays to keep parts and accessories may include one or more of the following:
fasteners organized, and an adequate set of hand tools.
• Hydraulic Pump
An approved engine repair stand will aid the work and
• Generator
help prevent personal injury or component damage.
• Air Conditioning Compressor
Special tools are listed and illustrated throughout this
• Cooling Fan
section with a complete listing at the end of the section.
• Distributor
These tools (or their equivalents) are specially designed
• TBI Unit
to quickly and safely accomplish the operations for
which they are intended. The use of these special tools It is beyond the scope of this section to cover in detail
will also minimize possible damage to engine compo the many different accessory installations. Refer to the
nents. appropriate Truck Service Manual for this information.
Some precision measuring tools are required for Diagrams of emissions and vacuum hose routings,
inspection of certain critical components. Torque wiring harness routing, accessory drive belt layout, etc.
wrenches are necessary for the correct assembly of should be found before removing accessories.
various parts.
4.3L V6 (V IN Z) 6A3B-9
CLEANING COOLANT PUMP REMOVAL

Remove the engine accessories before cleaning, to
provide better access to the engines exterior surfaces.
After removing the TBI unit, distributor, etc., cover the
openings with tape to prevent the entry of contami 1. Coolant pump bolts.
nants. 2. Coolant pump.
Methods used to clean the engine will depend on the 3. Gaskets.
means which are available. Steam cleaning, pressure
washing, or solvent cleaning are some of the accept ROCKER ARM COVER REMOVAL
able methods. Allow the engine to dry thoroughly before
beginning any work. Remove or Disconnect (Figure 6)
It is important that the engine be as clean as possible
to prevent dirt,coolant, or any other contaminants from 1. Rocker arm cover bolts (1).
entering critical areas during disassembly. 2. Rocker arm covers (2).
3. Gaskets.
DRAINING THE ENGINE
INTAKE MANIFOLD REMOVAL
|*--»| Remove or Disconnect
1. Oil pan drain plug and washer.
1. Intake manifold bolts.
• Allow the oil to drain into a proper container. 2. Intake manifold.
2. Oil filter. 3. Gaskets.
3. Coolant drain plug and or knock sensor from the
block. VALVE TRAIN COMPONENT
• Allow the coolant to drain from the block into a REMOVAL
proper container.
Important
+*■ Install or Connect
Store all reusable components in an exact order so
they can be reassembled in the same position from
NOTICE: For steps 1 and 2 refer to “Notice’ which they were removed.
on page 6A3B-1.
1. Oil pan drain plug and washer.
1. Rocker arm nuts (21,) balls (22), and rocker arms
Tighten (23).
& 2. Push rods (24).
• Drain plug to 25 N-m (18 lbs. ft.). 3. Bolt (19).
4. Guide assembly (20).
2. Coolant drain plug and or knock sensor into the 5. Hydraulic lifters (26).
block. • Remove the lifters one at a time and place
them in an organizer rack.
Tighten
CYLINDER HEAD REMOVAL
• Coolant drain plugs or knock sensor to 14 N-m
(124 lbs. in.). Remove or Disconnect
EGR VALVE REMOVAL 1. Engine lift bracket.

2. Cylinder head bolts.
|<-+| Remove or Disconnect 3. Cylinder heads.
4. Head gaskets.
1. Bolts.
2. EGR valve. TORSIONAL DAMPER REMOVAL
3. Gasket.
NOTICE: The inertial weight section of the
EXHAUST MANIFOLD REMOVAL torsional damper is assembled to the hub
with a rubber sleeve. The removal proce
|* + | Remove or Disconnect dures must be followed (with the proper
tools) or movement of the inertia weight sec
1. Exhaust manifold bolts, washers, and tab washers. tion of the hub will destroy the tuning of the
2. Heat shields. torsional damper and the engine timing refer
3. Exhaust manifold. ence.
6A3B-10 4.3L V6 (VIN Z)
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
Figure 7—Valve Train Components

4.3L V 6 (VIN Z) 6A3B-11
Tool Required:
J 39046 Torsional Damper Puller and Installer
1. Torsional damper bolt.

2. Torsional damper using J 39046 (figure 8).
3. Crankshaft key.
OIL PAN REMOVAL
4*+ Remove or Disconnect (Figure 9)
1. Oil pan nuts (125).

2. Oil pan bolts (129).
3. Clips (130) and studs (128).
4. Reinforcements.
Figure 8— Removing the Torsional Damper 5. Oil pan (72).
6. Gasket (70).
Figure 9—Oil Pan and Components

6A3B-12 4.3L V6 (VIN Z)
34. NUT
35. STUD
36. KEY
37. GEAR, BALANCE SHAFT DRIVE
38. SPROCKET, CRANKSHAFT
39. BOLT
40. SPROCKET, CAMSHAFT
41. CHAIN, TIMING
V2629
Figure 10—Camshaft and Components
OIL PUMP REMOVAL

1. Oil pump to main bearing cap bolt.

2. Complete oil pump assembly.
3. Shaft extension.
FLYWHEEL REMOVAL
1. Flywheel bolts.
2. Flywheel.
FRONT COVER REMOVAL

Figure 11—Removing the Crankshaft Sprocket
CAMSHAFT REMOVAL
1. Front cover bolts.
2. Front cover. ++ Remove or Disconnect (Figures 10 through
3. Front cover gasket.
12)
TIM ING CHAIN AND CAMSHAFT Tools Required:
SPROCKET REMOVAL J 5825-A Crankshaft Gear Remover
1. Balance shaft drive gear nut.
++ Remove or Disconnect (Figures 10 and 11)
2. Balance shaft drive gear (37).
3. Crankshaft sprocket (38), if necessary. Use J 5825
• Check timing chain free play. If the timing chain (figure 11).
can be moved back and forth in excess of 16 mm 4. Camshaft retainer bolts and camshaft retainer.
(5/8 inch), make a note that the timing chain should 5. Camshaft.
be replaced during assembly.
A. Install three 5/16-18 inch bolts 100-125 mm
1. Camshaft sprocket bolts (39) and nut (34). (4-5 inches) long into the camshafts threaded
2. Camshaft sprocket (40) and timing chain (41) holes. Use these bolts to handle the camshaft
together. (figure 12).
• The sprocket has a light interference fit on the
camshaft. Tap the sprocket on its lower edge to
loosen it.
4.3L V6 (VIN Z) 6A3B-13
5. Balance shaft (47) using a soft faced hammer (fig

ure 13).
6. Balance shaft rear bearing (45) using J 38834 and
J 26941.
Important
The balance shaft with front bearing are serviced

as an assembly
Use only the correct tools for bearing and shaft
installation.
Inspect the balance shaft driven gear and the drive
gear for nicks and burrs.
PISTON AND CONNECTING ROD

REMOVAL
Figure 12—Removing the Camshaft
Tools Required:
BALANCE SHAFT REMOVAL J 5239 Guide Set
J 24270 Ridge Reamer
«--► Remove or Disconnect (Figure 13) 1. Ridge or deposits from the upper end of the cylin
der bores as follows:
Tools Required: A. Rotate the crankshaft until the piston is at BDC.
J 38834 Balance Shaft Bearing Service Kit B. Place a cloth on top of the piston.
C. Perform the cutting operation with J 24270.
D. Rotate the crankshaft until the piston is at TDC.
1. Bolt (49). E. Remove the cloth and cuttings.
2. Driven gear (42). F. Repeat this procedure for each piston.
3. Retainer bolts (48). 2. Mark the cylinder numbers on the tops of each
4. Retainer (43). piston.
Figure 13—Removing Balance Shaft Assembly

6A3B-14 4.3L V6 (VIN Z)
A.
Figure 14— Removing the Cylinder Ridge
Figure 16—Seal Removal Notches
CRANKSHAFT REAR OIL

SEAL REMOVAL
NOTICE: When removing the crankshaft rear

oil seal, be careful to not damage the crank
shaft sealing surface. A minor scratch can
cause a major oil leak.
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
Figure 17—Crankshaft Rear Oil Seal Retainer

MAIN BEARING REMOVAL
(W ITHOUT REMOVING Tool required:
CRANKSHAFT) J 8080 Main Bearing Remover/Installer
1. Main bearing cap bolts.
V Important 2. Main bearing caps.
3. Lower main bearing inserts from the main bearing
Check the main bearing caps for location markings. caps.
Mark the caps if necessary. The caps must be 4. Upper main bearing inserts.
returned to their original locations during assembly. A. Insert J 8080 into the crankshaft oil hole (figure
18).
B. Rotate the crankshaft to turn the upper main
bearing insert out of the block.
CLEANING, INSPECTION, AND REPAIR

NOTICE: The following is recommended gas A solvent tank large enough to hold the larger engine
ket cleaning procedure for General Motors parts will be needed as well as various bristle brushes
engine components. Carefully remove all and gasket scrapers. A source of compressed air will
gasket material from the part using a plastic also be helpful in the cleaning operations.
or wood scraper. Use Loctite brand “Chisel Special tools are listed and illustrated throughout this
Gasket Remover” (P/N 79040) Permatex section with a complete listing at the end of the section.
brand “Gasket Remover" (P/N 4MA) or equiv These tools (or their equivalents) are specially designed
alent. Follow all safety recommendations and to quickly and safely accomplish the operations for
directions that are on the can. which they are intended. They should not be used in
Do not use any other method or technique to operations for which they are not designed. These spe
remove gasket material from a part. Do not cial tools, when they are properly used, will also mini
use abrasive pads, sand paper or power mize possible damage to engine.
tools to clean gasket surfaces. These meth Some precision measuring tools are required for
ods of cleaning can damage the part. Abra inspection of certain critical components. These include
sive pads also produce a fine grit that the oil micrometers, torque wrenches, feeler gages, dial indica
filter cannot remove from the oil. This grit is tor set, etc. The inspection work, when performed with
abrasive and has been known to cause inter the proper methods and tools, is most important. The
nal engine damage. rebuilt engine cannot be expected to perform properly if
the parts are worn beyond acceptable limits are reused.
NOTICE: If the engine is damaged internally

and needs to be rebuilt, make sure all foreign CYLINDER BLOCK
material is completely flushed out of the
co oling sy s te m /o il co ol er system (if Remove or Disconnect
equipped). Failure to flush out the debris can
result in damage to the rebuilt engine. 1. Oil pressure fitting and sensor.
2. Coolant drain plugs.
6A3B-16 4.3L V 6 (VIN Z)
3. Oil filter adapter bolts.

4. Oil filter adapter and gasket.
5. Camshaft an balance shaft cup plugs (89).
6. Front oil gallery cup plugs (86).
7. Rear oil gallery plugs (87, 88, and 90).
jjjjjl Clean (Figure 19)
• Sealing material from mating surfaces

• Boil cylinder block in caustic solution.
— Flush with clean water or steam.
• Cylinder bores.
• Threaded holes.
• Oil galleries and passages.
• Scale deposits from coolant passages.
• Spray or wipe cylinder bores and machined sur
faces with engine oil.
1. All expansion plugs for lack of fit or leakage.

2. Valve lifter bores for deep scratches and deposits.
3. Cracks in the block.
— Cylinder walls.
— Coolant jackets.
— Engine mount bosses.
— Main bearing webs.
4. Main bearing bores and caps.
• All main bearing bores should be rounded and
uniform in ID at all of the bearing supports.
• The area were the main bearing inserts contact
the main bearing bore should be smooth.
• If a main bearing cap is found to be damaged,
replace the cap and line-bore the block.
5. Cylinder head mounting surface for flatness, using
a precision straight edge and feeler gage (figure
20).
A. Set the straight edge on the sealing surface to
be inspected.
B. Take the feeler gage and at various locations,
check the gap between the straight edge and
the sealing surface.
C. If the gap is greater than 0.05 mm (0.002 inch)
within 152 mm (6 inches) at any sealing loca
tion, the block must be replaced.
D. If the gap is found to be less than 0.05 mm
(0.002 inch) at any sealing location and a cause
for leakage is suspected, then the minor irregu SECTION A-A
larities may be carefully machined from the
block.
6. Oil pan, timing cover, and intake manifold mounting
surfaces for nicks. Minor irregularities may be 45. BEARING
cleaned up with a flat file. 47. BALANCE SHAFT
86. CUP PLUGS
CYLINDER BORE 87. PLUG
88. PLUG
Inspect 89. CUP PLUGS
90. PLUG
• Cylinder bores for scoring or other damage.

V3293
|]| Measure
Figure 19—Engine Block Coolant Drain and Oil
• Cylinder bore taper and out-of-round. Refer to Gallery Plugs
SECTION 6A.
4.3L V 6 (VIN Z) 6A3B-17

ROD ASSEMBLY
Notice: The connecting rod, bearing and cap
need to be stored together as mating parts,
so they may be reassembled in the same
position from which they were removed.
Refer to SECTION 6A and perform the following:
* 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.
-►«- Install or Connect L* Inspect
Components as outlined.
NOTICE: For steps 2, 4, 5, and 6 refer to “No-
tice” on page 6A3B-1. € Measure
Piston pin diameter and clearance.

1. Front oil gallery plugs (86). Piston to bore clearance and fit of pistons.
• Coat plug outside diameter with sealant (GM Ring end gap and ring clearances.
P/N 1052080) or equivalent. Ring fit.
2. Rear oil gallery plugs (87, 88, and 90). * Assemble
Tighten Components as outlined.

The connecting rod and cap and check for identifi
• Plug (87) to 30 N-m (22 lbs. ft.). cation marks.
• Plug (88) to 40 N-m (30 lbs. ft.). The numbers on the connecting rod and bearing
• Plug (90) to 40 N m (30 lbs. ft.). cap. The connecting rod and bearing cap must be
on the same side when installed in the cylinder
3. Camshaft and balance shaft cup plugs (89) to
bore. If a connecting rod is ever transposed from
proper depth.
the block or cylinder, new connecting rod bearings
• Coat plug outside diameter with sealant (GM must be fitted and connecting rod should be num
P/N 1052080) or equivalent. bered to correspond with the new cylinder number.
4. Oil filter adapter, gasket, and bolts.
13 Inspect
Tighten
Ring fit.
INTAKE AND EXHAUST
5. Coolant drain plugs. MANIFOLDS
Tighten
| Clean
• Plugs to 20 N-m (15 lbs. ft.).
Mating surfaces on intake manifold and cylinder
6. Oil pressure fitting and sensor. head.
Excessive carbon buildup in the exhaust passages
£ Tighten of the intake manifold.
Scale and deposits from the coolant passages of
Fitting to 11 N-m (97 lbs. in.) plus turn for align the intake manifold.
ment if necessary. EGR passage of excessive carbon deposits.
6A3B-18 4.3L V6 (VIN Z)
Sprocket.
Keyway and threads.
— Galling
— Gouges
— Overheating
Measure
• Camshaft journal diameters (figure 22). Refer to

“Engine Specifications” in the back of this section
for proper diameters.
CAMSHAFT BEARINGS
Refer to SECTION 6A for replacement procedures.
A. Straight Edge TIM ING CHAIN AND

B. Feeler Gage
V0571
SPROCKETS
Figure 21—Checking Alignment of Manifold I? Inspect
Flanges
• Sprockets for chipped teeth and wear.
ffi Inspect (Figure 21) — Excessively worn sprockets will rapidly wear a
new chain.
• Manifolds for cracks, broken flanges, and gasket • Timing chain for damage.
surface damage. — An excessively worn chain will rapidly wear a
• Alignment of manifold flanges. Use a straight edge new set of sprockets.
and feeler gage. If the flanges do not align, the
manifold is warped and should be replaced. CRANKSHAFT SPROCKET REPLACEMENT

CAMSHAFT
Tool Required:
Important J 5825-A Crankshaft Sprocket Puller
1. Crankshaft sprocket using J 5825-A.
Do not attempt to repair the camshaft, replace it if 2. Key (if necessary).
damaged.
Whenever the camshaft is replaced, a new set of -►4- Install or Connect (Figure 23)
lifters must also be installed.
Tool Required:
I? Inspect J 5590 Crankshaft Sprocket Installer
1. Key (if removed).
Bearing surfaces and lobes for: 2. Crankshaft sprocket using J 5590.
— Wear
FRONT COVER
Clean
Old gasket from the gasket surfaces.
I? Inspect
Front cover for damage, dents, or cracks.
4-+ Remove or Disconnect
Oil seal from the front cover.

A. Pry the seal out with a large screwdriver.
B. Be careful not to distort the front cover.
Tool Required:
J 35468 Front Cover Aligner and Oil Seal
Installer
4.3L V 6 (V IN Z) 6A3B-19
J 35468
V0520
Figure—24 Installing Oil Seal (Cover Removed)
“lumpy” when turned, replace the coolant pump. If

the shaft end play exceeds 0.381 mm (0.015 inch),
replace the coolant pump.
• Coolant pump body at the drain (weep) hole. Slight
staining around the weep hole is normal. Replace
the coolant pump only if coolant is dripping from
the weep hole while the engine is running or while
the system is pressurized.
OIL PAN AND ROCKER ARM

COVERS
j|| Clean
• Parts in solvent. Remove all sludge and varnish.

• Old gaskets from the gasket surfaces.
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)
Pressure regulator valve (6) for fit. The regulator

valve should slide freely in its bore without sticking
or binding.
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
Figure 26— Installing the Oil Pump Screen

4.3L V6 (V IN Z) 6A3B-21
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
Whenever the camshaft needs to be replaced, a

new set of hydraulic lifters must also be installed.
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
* Disassemble (Figures 27 and 28)
Tool Required:
J 8062 Valve Spring Compressor
6A3B-22 4.3L V6 (VIN Z)
ROCKER ARM STUD REPLACEMENT

The 4.3L VIN Z engine has screw-in rocker arm studs
with positive stop shoulders. You must follow the
replacement procedures outlined below under “Screw-In
Studs.” No valve adjustment is necessary. When the
valve train requires service, you simply tighten the rock
er arm nuts 27 N m (20 lbs. ft.).
Rocker arm stud by unscrewing.
Install or Connect
• Rocker arm stud.
Tighten
• Rocker arm stud to 47 N-m (35 lbs. ft.).

XJJP Clean
• Components as outlined.
L1 Inspect
Components as outlined. Figure 29—Checking the Valve Seals
Measure A. Apply a small amount of grease to the area of

the upper valve stem groove.
• Valve stem clearance. B. Assemble the two valve keepers into the upper
• Valve spring tension and free length. groove using the grease to hold them in place.
Other information outlined includes: C. Release the compressor tool J 8062, making
• Valve and seat grinding. sure the valve keepers stay in place.
• Valve guide reaming. D. Repeat the preceding steps on the remaining
valves.
* Assemble (Figures 29)
1? Inspect
Tools Required:
J 8062 Valve Spring Compressor O-ring seals for leakage (figure 29).
J 23738-A Vacuum Pump
A. Place the suction cup supplied with J 23738-A
1. Valves (74 and 76).
over the shield.
A. Lubricate the valve stems with engine oil.
B. Connect J 23738-A to the suction cup and
B. Insert the valves (74 and 76) into the proper
apply a vacuum.
valve guides until the face of the valve contacts
C. Watch the vacuum pump gage, no air should be
the valve seat.
able to leak past the seal.
2. Seal (71) (intake valves only).
D. If the seal will not hold a vacuum, it may have
A. Install the seal (71) over the valve stem. been damaged or improperly installed.
B. Hold the valve (74) against the valve seat. E. Repeat the preceding steps on the remaining
C. Push the seal (71) down the valve stem until it valves.
bottoms out against the head.
3. Springs (73) and dampers (72). Measure
4. Shields (69).
5. Cap (68) or rotator (75).
• Valve spring installed height of each spring as fol
• Compress the valve spring using J 8062 (figure
lows:
28), enough so the lower valve stem groove can be
seen clearly. 1. Use a narrow thin scale. A cutaway scale may be
6. O-ring seal (70) onto the valve stem’s lower helpful.
groove, making sure the seal (70) is flat and not 2. From the top of the shim or the spring to the top of
twisted. the shield.
4.3L V6 (V IN Z) 6A3B-23
3. If this measurement exceeds the amount given in 1? Inspect

“Engine Specifications,” install valve spring seat
shims, approximately 1.6-mm (1/16-inch) thick, Crankshaft for cracks.
between the spring and cylinder head. NEVER
shim the spring so as to give an installed height — Use the magnaflux method, if available.
under the specified amount. — Crankpins, main bearing journals and thrust
surfaces for scoring, nicks or damage caused
THERMOSTAT AND COOLANT by lack of lubrication.
OUTLET — Main bearing inserts for scoring or other dam
age.
Measure
1. Bolts.
2. Stud. • Main bearing and connecting rod journal diameters
3. Coolant outlet. (figure 30). Compare with “Engine Specifications.”
4. Gasket. • Main bearing and connecting rod journals for taper
5. Thermostat (with gasket). and out-of-round.
L* Inspect • Maximum journal taper is 0.001 inch.

• Maximum out-of-round is 0.002 inch.
• Coolant outlet for cracks.
• Crankshaft run-out.
Install or Connect A. Mount the crankshaft in V-blocks or between
centers.
1. Thermostat. B. Use a dial indicator.
2. New gasket. C. If the main journals are misaligned, the crank
3. Coolant outlet.
shaft is bent and must be replaced. The main
NOTICE: Refer to “Notice” on page 6A3B-1. bearings must also be replaced at the same
time.
4. Bolt. D. Grind or replace the crankshaft if necessary.
5. Stud.
In general, the lower inserts (except the # 1 bearing)
Tighten show the greatest wear and distress from fatigue. Upon
inspection, if a lower insert is suitable for reuse, it can
Bolts to 28 N-m (21 lbs. ft.). be assumed that the upper insert is also satisfactory. If
Stud to 28 N-m (21 lbs. ft.). a lower insert shows evidence of wear or damage, both
the upper and lower inserts must be replaced.
TORSIONAL DAMPER
1? Inspect
Torsional damper weight for signs of shifting on the

hub. Replace as needed. Area of the torsional damper
hub shaft that contacts the front crankshaft seal for
roughness or nicks. Replace the damper if this condi
tion exists. If damper is replaced, new balance weights
of the same size must be installed on the new damper
in the same location as the old damper.
CRANKSHAFT AND BEARINGS

Some engines may have rear main bearings that are
0.008 inch wider than standard across the thrust faces.
The crankshaft on these engines can be identified by
“.008”stamped on the rear counterweight.
Kyi Clean
• Crankshaft with solvent.

— Do not scratch the bearing journals.
— Remove all sludge from the oil passages with A. Micrometer
compressed air. V0573
• Main bearing inserts.
— Wipe free of oil with a soft cloth. Figure 30— Measuring the Crankshaft Journals
6A3B-24 4.3L V6 (VIN Z)
ASSEMBLY OF THE ENGINE

PRIOR TO ASSEMBLY 1. Upper main bearing inserts to the block.
The importance of cleanliness during the assembly Important

procedure cannot be overstressed. Dirt will cause pre
mature wear of the rebuilt engine.
Lubricate all moving parts lightly with engine oil or • If any undersized bearings are used, they must
engine assembly lubricant (unless otherwise specified) be fitted to the proper journals.
during assembly. This will provide initial lubrication 2. Crankshaft.
when the engine is started. 3. Lower main bearing inserts to the main bearing
caps.
CRANKSHAFT AND MAIN
BEARING INSTALLATION Measure
Main bearings are of the precision insert type and do
not use shims for adjustment. If clearances are exces • Main bearing clearance. Refer to SECTION 6A.
sive, both upper and lower bearing inserts will be
• Apply engine oil to the main bearing inserts.
required. Service bearings are available in standardize
and 0.001-inch, 0.002-inch, 0.009-inch, 0.010-inch and 4. Main bearing caps (except rear cap) and bolts to
0.020-inch undersize. the block.
Selective fitting of both rod and main bearing inserts
is necessary in production to obtain close tolerances. Tighten
For this reason you may find one half of a standard £
insert with one half of a 0.001-inch undersize insert
which will decrease the clearance 0.0005 inch from • Main bearing cap bolts (except rear cap) to 110
using a full standard bearing. N-m (81 lbs. ft.).
Some engines may have rear main bearings that are 5. Rear main bearing cap.
0.008-inch wider than standard across the thrust faces. 6. Rear main bearing cap bolts.
• The crankshaft on these engines can be identified
by “.008”stamped on the rear counterweight. Tighten
• If the rear main bearings are replaced, they must
have the proper distance between thrust faces to •R e a r main bearing cap bolts to 14 N-m (124
obtain proper crankshaft end play.
lbs. in.).
INSPECTING CRANKSHAFT END PLAY
Measure
■H" Install or Connect
Crankshaft end play, as follows:
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
•T h e rear main bearing cap bolts to 110 N-m (81

lbs. ft.).
Measure
• With the crankshaft wedged forward, measure at

the front end of the rear main bearing with a feeler
gage (figure 31). The proper clearance is
0.051-0.152 mm (0.005 to 0.018 inch).
• If correct end play cannot be obtained, be certain
that the correct size rear main bearing has been
installed.
• Production engines may have rear main bearings
A. Feeler Gage
V0577 that are 0.008 inch wider across the thrust faces
than standard.
Figure 31—Measuring Crankshaft End Play
4.3L V6 (VIN Z) 6A3B-25
m Inspect
Crankshaft for binding. Try turning the crankshaft to

check for binding. If the crankshaft does not turn
freely, loosen the main bearing cap bolts one pair
at a time until the tight bearing is located. Burrs on
the bearing cap, foreign matter between the insert
and the block or the bearing cap, or a faulty insert
could cause a lack of clearance at the bearing.
Tighten
•A ll main bearing cap bolts to 110 N-m (81 lbs. ft.).

RETAINER INSTALLATION
y | Clean
Figure 33—Installing the Crankshaft Rear Oil Seal
• Gasket surfaces on the block and seal retainer.
Crankshaft rear oil seal.
+ 4- Install or Connect (Figure 32)
A. Lubricate the inner and outer diameter of the
1. New gasket (54) to the block. seal with engine oil.
• It is not necessary to use sealant to hold the B. Install the seal on J 35621.
gasket in place. C. Position J 35621 against the crankshaft. Thread
2. Seal retainer (52). the attaching screws into the tapped holes in
the crankshaft.
NOTICE: Refer to “Notice” on page 6A3B-1. D. Tighten the screws securely with a screwdriver.
3. Screws (50) and nuts (51). This will ensure that the seal is installed
squarely over the crankshaft.
& Tighten E. Turn the handle until it bottoms.
F. Remove J 35621.
• Screws and nuts to 15 N-m (11 lbs. ft.).
CAMSHAFT INSTALLATION
CRANKSHAFT REAR OIL
SEAL INSTALLATION Install or Connect (Figures 34 and 35)
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.
3. Camshaft retainer and retainer bolts.
52 £ Tighten
V0516 Bolts to 14 N-m (124 lbs. in.).

Figure 32—Crankshaft Rear Oil Seal Retainer
6A3B-26 4.3L V6 (VIN Z)
34. NUT
35. STUD
36. KEY
39. BOLT
40. SPROCKET, CAMSHAFT
41. CHAIN, TIMING
V2629
B. Retaining ring on balance shaft front bearing

must be seated on case.
3. Install balance shaft bearing retainer (43) and bolts
(48).
Tighten
• Balance shaft retainer bolts (48) to 14 N-m (124

lbs. in.).
4. Balance shaft driven gear (42) and bolt (49).
Tighten
• Balance shaft driven gear bolt (49) to 20 N-m

(15 lbs. ft.) plus an additional turn of 35
degrees using J 36660.
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 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
Figure 36—installing Balance Shaft and Components
TIM IN G CHAIN AND

SPROCKET INSTALLATION
+ 4* Install or Connect (Figures 37 and 38)
1. Camshaft sprocket and timing chain.
Important
• Line up the timing marks on the camshaft

sprocket and crankshaft sprocket (figure 38).
• The number 4 cylinder is at top dead center of
the compression stroke with the timing marks in
this position (figure 38).

2. Camshaft sprocket bolts (39) and nut (34).
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)
NOTICE: Refer to “N otice” on page 6A3B-1.

FRONT COVER INSTALLATION
5. Torsional damper bolt and washer.
++ Install or Connect
& Tighten
1. Front cover gasket to the front cover.
• Use gasket cement to hold the gasket in place. • Bolt to 95 N.m (70 lbs. ft.).
2. Front cover to the engine.

ROD INSTALLATION
CONNECTING ROD BEARING SELECTION
Tighten Connecting rod bearings are of the precision insert
type and do not use shims for adjustment. DO NOT
Front cover to block bolts to 14 N-m (124 lbs. FILE RODS OR ROD CAPS. If clearances are exces
in.). sive, install a new bearing. Service bearings are avail
able in standard size and 0.0014-mm undersize for use
TORSIONAL DAMPER with new and used standard size crankshafts.
INSTALLATION +*• Install or Connect (Figures 40 through 42)
++ Install or Connect (Figure 39) Tools Required:

J 5239 Connecting Rod Guide Set
Tool Required: J 8037 Ring Compressor
J 39046 Torsional Damper Puller and Installer J 36660 Torque/Angle Meter
1. Crankshaft key (if removed).
• Lubricate the cylinder walls lightly with engine oil.
NOTICE: The inertial w eight s e c tio n o f th e • Make sure the piston is installed in the matching
torsional dam per is a ssem b led to the hub cylinder.
with rubber type material. The correct instal 1. Connecting rod bearings.
lation procedures with the proper tool) m u st A. Make sure that the bearing inserts are of the
b e follow ed or m o v e m e n t o f th e inertial proper size.
w eig h t s e c tio n o f th e h u b will d e s tr o y th e B. Install the bearing inserts in the connecting rod
tuning o f the torsional damper. and connecting rod cap.
C. Lubricate the bearings with engine oil.
2. Stud (item A, figure 39) to the crankshaft. Thread
the stud fully into the tapped hole in the crankshaft. 2. Piston and connecting rod into the proper bore.
3. Torsional damper over the end of the stud. Align A. With the connecting rod cap removed, install
the keyway in the torsional damper shaft with the J 5239 onto the connecting rod bolts (figure
crankshaft key. 40).
4. Bearing, washer, and nut (figure 39). B. Locate the piston ring end gaps (figure 41).
A. Turn the nut to pull the vibration damper into Lubricate the piston and rings with engine oil.
place. C. Without disturbing the ring end gap location,
B. Remove the tool. install J 8037 over the piston.
4.3L V6 (VIN Z) 6A3B-29
D. The piston must be installed so that the notch

in the piston faces the front of the engine (fig
ure 41).
E. Place the piston in its matching bore. The con
necting rod bearing tang slots must be on the
side opposite the camshaft. Using light taps
with a hammer handle, tap the piston down into
its bore (figure 42). Guide the connecting rod to
the crankpin with J 5239 (figure 40). Hold the
ring compressor against the block until all rings
have entered the cylinder bore.
F. Remove J 5239 from the connecting rod bolts.
Important
Each connecting rod and bearing cap should be

marked, beginning at the front of the engine.
Cylinders 1, 3, and 5 are the right bank and 2,
4, and 6 are the left bank (when viewed from
the front of the engine). The numbers on the
connecting rod and bearing cap must be on the
same side when installed in the cylinder bore. If
a connecting rod is ever transposed from one
Figure— 42 Installing the Piston
block or cylinder to another, new connecting rod

bearings should be fitted and the connecting
rod should be numbered to correspond with the
new cylinder number.
3. Connecting rod cap with bearing insert and nut.
tjj Measure
Connecting rod bearing clearance. Refer to

SECTION 6A.
& Tighten
Connecting rod bolt nuts to 27 N-m (20 lbs. ft.).

Connecting rod bolt nuts an additional 70
Measure
Connecting rod side clearance (figure 43). The

proper clearance is 0.015 to 0.046 inch.
OIL PUMP INSTALLATION

A. Oil Ring Rail Gaps
B. 2nd Compression Ring Gap Install or Connect
G Notch In Piston
0. Oil Ring Spacer Gap 1. Oil pump to the engine.
(Tang In Hole Or Slot With Arc) • Align the slot in the oil pump shaft with the tang
on the distributor shaft.
E. Top Compression Ring Gap B7895
• The oil pump should slide easily into place.
Figure—41 Piston Ring End Gap Location • No gasket is used.
6A3B-30 4.3L V6 (VIN Z)
Clearance
Tighten
’ Oil pump to main bearing cap bolt to 88 N-m

(65 lbs. ft.).
OIL PAN INSTALLATION

++ Install or Connect (Figure 44)
•Apply RTV sealant (GM P/N 12346141) or equiva

lent to the front cover to block joint and to the 27. Gasket 82. Nut
crankshaft rear retainer seal to block joint. Apply 28. Reinforcement 83. Bolt
the sealant about 25 mm (1 inch) in both directions 29. Oil Pan 84. Stud
V0509
from each of the four corners (figure 44).
1. Oil pan gasket (27) to the block. Figure 44—Oil Pan and Components
2. Oil pan (29) to the gasket (27).
3. Reinforcements (28).
4. Oil pan clips, bolts (83), nuts (82), and studs (84). 0 0 ®
Tighten © 0 0 0
• Bolts (83) and studs (84) to 11 N-m (97 lbs. in.).
• Four corner nuts (82) to 23 N-m (17 lbs. ft.).
CYLINDER HEAD INSTALLATION 4 i FRONT

t2» Clean B7874
Figure 45—Cylinder Head Bolt Tightening

• Gasket surfaces on the block and cylinder head. Sequence
Install or Connect (Figure 45) NOTICE: Refer to “N otice” on page 6A3B-1.
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.
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

6A3B-32 4.3L V6 (VIN Z)
V2974
Figure 47—Intake Manifold and Components

4.3L V6 (VIN Z) 6A3B-33
2. RTV to the front and rear sealing surfaces on the

block. Apply a 5-mm (3/16-inch) bead of RTV (GM
P/N 1052366) or equivalent to the front and rear of
the block as shown in figure 47. Extend the bead
13 mm (1/2 inch) up each cylinder head to seal
and retain the gaskets.
3. Intake manifold to the engine.
4 FRT (g)(f
INITIAL TIGHTENING SEQUENCE
4. Intake manifold bolts.
a Tighten
A. Intake manifold bolts to 47 N-m (35 lbs. ft.)

using the tightening sequence shown in figure
48.
4 FRT B. Retorque, intake manifold bolts using the tight
ening sequence shown in figure 48.
FINAL TIGHTENING SEQUENCE ROCKER ARM COVER

INSTALLATION
A. Bolt 56 N m (41 ft.lbs)
All Other Bolts 47 N-m (35 ft.lbs) 1. Rocker arm cover (2 or 3).
2. New gasket.
B7873

Figure 48—intake Manifold Bolt Tightening
Sequence
3. Rocker arm cover bolts (1) and washers.
Figure 49—Rocker Arm Cover and Components

6A3B-34 4.3L V6 (VIN Z)
Figure 50—Exhaust Manifolds and Components
£ Tighten EGR VALVE INS' ION

• Rocker arm cover bolts (1) to 10 N m (90 lbs. +«- Install or Connect
in.).
1. New gasket.
EXHAUST MANIFOLD 2. EGR valve.
INSTALLATION
NOTICE: Refer to “N otice” on page 6A3B-1
install or Connect (Figure 50)
3. Bolts.
1. Exhaust manifold.
2. Heat shield. a Tighten
NOTICE: Refer to “Notice” on page 6A3B-1. • Bolts to 22 N-m (16 lbs. ft.).
3. Exhaust manifold bolts, washers, and tab washers. FLYWHEEL INSTALLATION

Tighten Install or Connect
a
A. Bolts on center exhaust tube to 36 N-m (26 lbs. 1. Flywheel.
ft.).
B. Bolts on front and rear exhaust tubes to 28 N-m NOTICE: Refer to “N otice” on page 6A3B-1.
(20 lbs. ft.).
C. Bend the tab washers over the heads of all 2. Flywheel bolts.
bolts.
Tighten

4.3L V6 (VIN Z) 6A3B-35
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
If a new camshaft or hydraulic lifters were

installed, add Engine Oil Supplement (GM P/N
1052367) or equivalent to the engine oil.
6A3B-36 4.3L V6 (VIN Z)
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:
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
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
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.)
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
1. TORSIONAL DAMPER REMOVER AND INSTALLER 9. REAMER (0.003 INCH OVERSIZE)

2. VALVE SPRING COMPRESSOR 10. REAMER (0.013 INCH OVERSIZE)
3. CRANKSHAFT SEAL INSTALLER 11. STUD INSTALLER
4. MAIN BEARING REPLACER 12. CRANKSHAFT GEAR PULLER
5. PISTON RING COMPRESSOR 13. CRANKSHAFT GEAR INSTALLER
6. GUIDE SET 14. REAR CRANKSHAFT SEAL INSTALLER
7. VACUUM PUMP 15. TORQUE/ANGLE METER
8. STUD REMOVER 3706r4983
abECivr ioore
S3JLON
-----------
4 .3 L V6 (VIN W) 6A4B-1
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
• 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
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
Front C o ver..........................................................................................................................................................6A4B-19
Coolant Pum p......................................................................................................................................................6A4B-19
Oil Pan and Rocker Arm C overs................................................................................................................... 6A4B-20
Oil Pump............................................................................................................................................................... 6A4B-20
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
Torsional Dam per.............................................................................................................................................. .6A4B-23
Crankshaft Rear Oil Seal Retainer................................................................................................................. 6A4B-24
Flywheel................................................................................................................................................................ 6A4B-24
Assembly of the Engine........................................................................................................................................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
Piston and Connecting Rod Installation.......................................................................................................6A4B-29
Connecting Rod Bearing Selection............................................................................................................ 6A4B-29
Oil Pump 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
Exhaust Manifold Installation........................................................................................................................... 6A4B-34
EGR Valve Installation.......................................................................................................................................6A4B-34
Flywheel Installation........................................................................................................................................... 6A4B-35
Engine Set-up and Testing............................................................................................................................... 6A4B-35
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)
Figure 1—Cylinder Block and Components

4.3L V6 (VIN W) 6A4B-5
31. BOLT, OIL PUMP 143. GASKET, FRONT COVER

56. PUMP, OIL 144. INSERT, UPPER MAIN BEARING
57. SCREEN, OIL PUMP 145. KEY, WOODRUFF
58. SHAFT, OIL PUMP DRIVE 148. CAMSHAFT
59. PIN 149. GASKET, COOLANT PUMP
60. SPRING, OIL PRESSURE RELIEF 150. BOLT/STUD, COOLANT PUMP
61. VALVE, OIL PRESSURE REGULATOR 151. PUMP, COOLANT
62. PLUG 152. SPROCKET, CRANKSHAFT
64. RETAINER, OIL PUMP DRIVE SHAFT 153. BOLT
65. COVER, OIL PUMP 154. SPROCKET CAMSHAFT
70. GASKET, OIL PAN 155. CHAIN, TIMING
71. REINFORCEMENT, OIL PAN 156. BEARING, CAMSHAFT
72. PAN, OIL 158. TUBE, OIL LEVEL INDICATOR
80. SCREW, SEAL RETAINER 160. BOLT
81. NUT, SEAL RETAINER 161, PIN, PISTON
82. RETAINER, SEAL 187. BOLT, BALANCE SHAFT DRIVEN GEAR
83. STUD, SEAL RETAINER 188. GEAR, BALANCE SHAFT DRIVEN
84. GASKET, SEAL RETAINER 189. GEAR, BALANCE SHAFT DRIVE
87. RETAINER, CAMSHAFT 190. RETAINER, BALANCE SHAFT
88. SCREW, CAMSHAFT RETAINER 191. SHAFT, ENGINE BALANCE
90. SEAL 192. SCREW, BALANCE SHAFT RETAINER
91. GASKET 193. BEARING, BALANCE SHAFT REAR
92. ADAPTER 194. PLUG, CUP
93. BOLT 195. NUT, CAMSHAFT SPROCKET
94. FITTING 196. STUD, CAMSHAFT SPROCKET
100. CAP, MAIN BEARING 207. PLUG, HEX
101. CRANKSHAFT 208. SEAL, BALANCE SHAFT REAR BEARING PLUG
102. FILTER, OIL 209. PLUG, EXPANSION CUP
103. RINGS, PISTON 210. PLUG, SQUARE
104. PISTON 211. PIN, DOWEL
105. ROD, CONNECTING 212. PLUG, HEX
106. BEARING, CONNECTING ROD 213. PLUG, KNOCK SENSOR HOLE
107. CAP, CONNECTING ROD BEARING 214. PLUG, OIL PRESSURE
108. NUT, CONNECTING ROD BOLT 215. VALVE, OIL FILTER BYPASS
114. BLOCK, ENGINE 216. PLUG, OIL GALLERY
128. STUD, OIL PAN 217. GEAR, FLYWHEEL RING
129. BOLT, OIL PAN 218. PIN, OIL PRESSURE RELIEF VALVE SPRING
130. CLIP 219. PLUG, OIL PAN DRAIN
132. BOLT MAIN BEARING CAP 220. GASKET, OIL PAN DRAIN PLUG
133. PIN, GROOVE 221. PIN
134. FLYWHEEL 222. NUT, HEX
135. BOLT, FLYWHEEL 223. NUT, HEX
136. INSERT, LOWER MAIN BEARING 224. BEARING, BALANCE SHAFT FRONT
137. SEAL, CRANKSHAFT FRONT OIL 225. PLUG, OIL PRESSURE
138. DAMPER. CRANKSHAFT TORSIONAL 226. PLUG, HEX
139. PIN, GROOVE 228. FITTING, OIL PRESSURE GAGE
141. BOLT 229. SENSOR, OIL PRESSURE GAGE
142. COVER, FRONT 230. SENSOR, KNOCK
V3923
Figure 2—Cylinder Block and Components - Legend

6A4B-6 4.3L V6 (VIN W)
Figure 3—Cylinder Head, Manifolds, and Components

4.3L V6 (VIN W) 6A4B-7
20. KEY, VALVE STEM 179. MANIFOLD, EXHAUST

21. CAP, INLET VALVE SPRING 186. STUD, INTAKE MANIFOLD
22. SHIELD, VALVE STEM OIL 195. BOLT, UPPER INTAKE MANIFOLD
24. SEAL, INLET VALVE STEM 196. NUT, UPPER INTAKE MANIFOLD
26. SPRING, VALVE, WITH DAMPER 197. MANIFOLD, UPPER INTAKE
27. VALVE, INLET 198. GASKET, UPPER INTAKE MANIFOLD
28. ROTATER, EXHAUST VALVE 200, SUPPORT, SPARK PLUG WIRE
29. VALVE, EXHAUST 201. STUD, UPPER INTAKE MANIFOLD
40. BOLT, LIFTER RESTRICTOR RETAINER 202. COIL, IGNITION
41. RETAINER, VALVE LIFTER GUIDE 203. BRACKET, ENGINE LIFT REAR
42. NUT, VALVE ROCKER ARM 204. BOLT, LOWER INTAKE MANIFOLD
43. BALL, VALVE ROCKER ARM 205. BRACKET, ENGINE LIFT, FRONT
44. ARM, VALVE ROCKER 206. MANIFOLD, LOWER INTAKE
45. ROD, VALVE PUSH 231. GROMMET, CRANKCASE VENT VALVE
46. GUIDE, VALVE LIFTER 232. VALVE, CRANKCASE VENT
47. LIFTER, VALVE 241. CAP, OIL FILL
50. BOLT, CYLINDER HEAD 242. GROMMET, CRANKCASE VENT TUBE
54. GASKET, CYLINDER HEAD 243. TUBE, OIL FILL
60. SHIELD, HEAT 244. SUPPORT, SPARK PLUG WIRE
61. WASHER 245. SUPPORT, SPARK PLUG WIRE
62. LOCK, EXHAUST MANIFOLD 246. BOLT
63. BOLT/STUD, EXHAUST MANIFOLD 247. SPARK PLUG
163. BOLT, COOLANT OUTLET 248. SENSOR, KNOCK
164. OUTLET, COOLANT 249. PIN, DOWEL
165. GASKET, COOLANT OUTLET 250. SUPPORT, SPARK PLUG WIRE
166. THERMOSTAT 251. BOLT
168. SENSOR, ENGINE COOLANT TEMPERATURE 252. SENSOR, ENGINE COOLANT TEMPERATURE
174. VALVE, EGR 700. BOLT
176. GASKET, INTAKE MANIFOLD 701. COVER, VALVE ROCKER ARM
702. GASKET, VALVE ROCKER ARM COVER
V3925
Figure 4— Cylinder Head, Manifolds, and Components - Legend

6A4B-8 4.3L V6 (VIN W)
V0503
Figure 5—Engine Lubrication Flow

TOOLS AND SHOP EQUIPMENT ACCESSORY REMOVAL
A clean, well-lit, work area should be available. Other The various procedures in this manual assume that
necessary equipment includes: a suitable parts cleaning the engine accessories have been removed. These
tank, compressed air supply, trays to keep parts and accessories may include one or more of the following:
An approved engine repair stand will help aid with the • Power Steering Pump
work and help prevent personal injury or component • Drive Belt Tensioner
damage. • Generator
Special tools are listed and illustrated throughout this • Air Conditioning Compressor
section with a complete listing at the end of the section. • Cooling Fan
These tools (or their equivalents) are specially designed • Distributor
to quickly and safely accomplish the operations for
It is beyond the scope of this section to cover in detail
which they are intended. The use of these special tools
the many different accessory installations. Refer to the
will also minimize possible damage to engine compo
proper on-vehicle Light Duty Truck Service Manual for
nents.
this information.
Some precision measuring tools are required for
Diagrams of emissions and vacuum hose routings,
inspection of certain critical components. Torque
wiring harness routing, accessory drive belt layout, etc.
wrenches are necessary for the correct assembly of
should be found or made before removing accessories.
various parts.
4.3L V6 (VIN W) 6A4B-9
CLEANING ROCKER ARM COVER REMOVAL

Remove the engine accessories before cleaning to
provide better access to the engine’s exterior surfaces.
After removing the distributor, accessory brackets, etc.,
cover the openings with tape to prevent the entry of 1. Rocker arm cover bolts (1).
2. Rocker arm cover (2).
contaminants.
3. Gasket.
Methods used to clean the engine will depend on the
means which are available. Steam cleaning, pressure
washing, or solvent cleaning are some of the accept EGR VALVE REMOVAL
able methods. Allow the engine to dry thoroughly before
beginning any work. Remove or Disconnect (Figure 7)
It is important that the engine be as clean as possible
to prevent dirt, water, or any other contaminants from 1. Bolts.
entering critical areas during disassembly. 2. Exhaust gas recirculation (EGR) valve (85).
3. Gasket.
DRAINING THE ENGINE
UPPER INTAKE MANIFOLD
Remove or Disconnect REMOVAL
1. Oil pan plug and washer and allow the oil to drain Remove or Disconnect (Figure 7)
from the pan.
2. Oil filter.
1. Plastic cover (81).
3. Coolant drain plugs from the block and allow the 2. Upper intake manifold bolts (14), nuts (15), ignition
coolant to drain. coil (6) and stud (5).
3. Upper intake manifold (18), support (86), and gas
-H- Install or Connect ket (16).
LOWER INTAKE MANIFOLD

NOTICE: For ste p s 1 and 3, refer to “Notice ’
on page 6A4B-1. REMOVAL
Important
1. Coolant drain plugs into the block.
Make sure the ends of the fuel lines are properly
Tighten sealed.
• 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
• Oil pan drain plug to 25 N m (18 lbs. ft.).
EXHAUST MANIFOLD REMOVAL

1. Exhaust manifold bolts, washers, and tab washers.

2. Heat shields.
COOLANT PUMP REMOVAL

1. Coolant pump bolts.

2. Coolant pump.
3. Gaskets. Figure 6— Rocker Arm Cover and Components
6A4B-10 4.3L V6 (VIN W)
VALVE TRAIN COMPONENT

REMOVAL
Important
Store all reusable components in an exact order,

so they can be reassembled in the same wear
pattern location from which they were removed.
Mark the front end of the retainer (20).
<«► Remove or Disconnect (Figure 8)
1. Rocker arm nuts (21), balls (22), and rocker arms

(23).
2. Pushrods (24).
3. Bolts (19), retainer (20), restrictors (25), and
hydraulic lifters (26).
4. Guide assembly (20).
5. Hydraulic lifters (26).
Figure 7—Intake Manifold Assembly
• Remove the lifters one at a time and place
2. Lower intake manifold, lift brackets, and gaskets. them in an organizer rack.
Important CYLINDER HEAD REMOVAL

• Do not disassemble the CPI unit. It is only serviced Remove or Disconnect
as an assembly. For information on the upper and
lower intake manifold components, refer to the 1. Spark plugs.
Driveability, Emissions, and Electrical Diagnosis 2. Cylinder head bolts.
Manual for the appropriate model vehicle. 3. Cylinder heads.
4. Head gaskets.
19. BOLT
20. GUIDE ASSEMBLY
21. NUT
22. BALL
23. ARMS, ROCKER
24. PUSHROD
3706S2910

4.3L V6 (VIN W) 6A4B-11
Figure 9—Removing Torsional Damper
TORSIONAL DAMPER REMOVAL
NOTICE: The inertial w eig h t s e c tio n o f the

torsional dam per is a ssem b led to the hub
with a rubber sleeve. The rem oval p ro ce
du res m u st b e follow ed (with the proper
tools) or m ovem ent o f the inertial weight se c
tion o f the hub will destroy the tuning o f the
torsional dam per and the engine timing refer
ence.
*--► Remove or Disconnect (Figure 9)

27. Gasket 82. Nut
Tool Required: 28. Reinforcement 83. Bolt
J 39046 Harmonic Balancer Remover and 29. Oil Pan 84. Stud
V0509
Installer
Figure 10—Oil Pan and Components
1. Torsional damper bolt.
2. Torsional damper using J 39046. FLYWHEEL REMOVAL
3. Crankshaft key.
OIL PAN REMOVAL
1. Flywheel bolts.
4--¥ Remove or Disconnect (Figure 10) 2. Flywheel.
1. Oil pan nuts (82). FRONT COVER REMOVAL

2. Oil pan bolts (83).
3. Oil pan clips and studs (84).
++ Remove or Disconnect
4. Reinforcements (28).
5. Oil pan (29).
6. Gasket (27). 1. Front cover bolts.
2. Front cover.
3. Front cover gasket.
OIL PUMP REMOVAL
1. Bolt (31), oil pump to main bearing cap.

2. Complete oii pump assembly (30).
3. Shaft extension (32) and retainer (33).
6A4B-12 4.3L V6 (VIN W)
TIM IN G CHAIN AND CAMSHAFT

30. Pump Assembly
SPROCKET REMOVAL 31. Bolt
Remove or Disconnect (Figure 12) 32. Shaft Extension
33. Retainer
• Check timing chain free play. If the timing chain
can be moved back and forth in excess of 16 mm
(5/8 inch), make a note that the timing chain should
be replaced during assembly.
1. Camshaft sprocket bolts (39) and nut (34).
2. Camshaft sprocket (40) and timing chain (41)
together.
• The sprocket has a light interference fit on the
camshaft. Tap the sprocket on its lower edge to
loosen it.
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
34. NUT
35. STUD
36. KEY
38. SPROCKET CRANKSHAFT
39. BOLT
40. SPROCKET CAMSHAFT
41. CHAIN, TIMING
V2629

4.3L V6 (VIN W) 6A4B-13
J 5825-A
Figure 13— Removing Crankshaft Sprocket Figure 14— Removing Camshaft
Important PISTON AND CONNECTING ROD

REMOVAL
The balance shaft with front bearing are serviced
as an assembly.
++ Remove or Disconnect (Figures 16 and 17)
Use only the correct tools for bearing and shaft
installation.
Inspect the balance shaft driven gear and the drive Tools Required:
gear for nicks and burrs. J 5239 Guide Set
J 24270 Ridge Reamer
Figure 15— Removing Balance Shaft Assembly

6A4B-14 4.3L V6 (VIN W)
1. Ridge or deposits from the upper end of the cylin

der bores as follows:
A. Rotate the crankshaft until the piston is at BDC.
B. Place a cloth on top of the piston.
C. Perform the cutting operation with a J 24270
Ridge Reamer.
D. Rotate the crankshaft until the piston is at TDC.
E. Remove the cloth and cuttings.
F. Repeat this procedure for each piston.
2. Mark the cylinder numbers on the tops of each
piston.
engine in an upright position and viewed from
the front.
— The right bank is numbered 1-3-5.
3. Check the connecting rod and cap for identification
marks.
CRANKSHAFT REAR OIL
• Mark the parts. SEAL REMOVAL
engine in an upright position and viewed from Remove or Disconnect (Figure 18)
the front.
— The right bank is numbered 1-3-5. NOTICE: Take care when removing the rear
— The left bank is numbered 2-4-6. crankshaft oil seal s o a s not to dam age the
crankshaft sealing surface. A minor scratch
Important
can cause a major oil leak.
• Crankshaft rear oil seal. Insert a screwdriver into
• Store the connecting rod and cap together as mat the notches provided in the seal retainer and pry
ing parts, so they may be reassembled in the same the seal out.
wear pattern and balance from which they were
removed.
4. Connecting rod cap.
RETAINER REMOVAL
5. Connecting rod and piston. 4- + Remove or Disconnect (Figure 19)
A. Attach J 5239 to the connecting rod bolts.
B. Use the long guide rod J 5239 to push the con 1. Screws (50) and nuts (51).
necting rod and piston out of the bore through 2. Seal retainer (52).
3. Gasket (54).
the top of the engine.
6. Connecting rod bearings.
Figure 16—Removing Cylinder Ridge Figure 18—Seal Removal Notches

4.3L V6 (VIN W) 6A4B-15
B7879
Figure 19—Crankshaft Rear Oil Seal Retainer Figure 20— Removing Main Bearing Insert
CRANKSHAFT REMOVAL MAIN BEARING REMOVAL

The crankshaft need not be removed for replacement (W ITHOUT REMOVING
of rear oil seal or main bearings. These procedures are CRANKSHAFT)
covered in other sections of this manual.
Important
Important
Check the main bearing caps for location markings.
Check the main bearing caps for location markings. Mark the caps if necessary. The caps must be
Mark the caps if necessary. The caps must be returned to their original locations during assembly.
returned to their original locations during assembly.
4- + Remove or Disconnect (Figure 20)
Tool Required:
1. Main bearing cap bolts. J 8080 Main Bearing Shell Remover and
2. Main bearing caps and lower main bearing inserts. Installer
3. Crankshaft from the cylinder block with extreme
care, taking care to avoid damage to crankshaft 1. Main bearing cap bolts.
journals and thrust flange surfaces. 2. Main bearing caps.
4. Upper main bearing inserts. 3. Lower main bearing inserts from the main bearing
caps.
4. Upper main bearing inserts.
• Insert J 8080 into the crankshaft oil hole (figure
20).
• Rotate the crankshaft to turn the upper main
bearing insert out of the block.

A solvent tank large enough to hold the larger engine These special tools, when they are properly used, will
parts will be needed, as well as various bristle brushes also minimize possible damage to engine components.
and gasket scrapers. A source of compressed air will Some precision measuring tools are required for
also be helpful in the cleaning operations. inspection of certain critical components. These include
Special tools are listed and illustrated throughout this micrometers, torque wrenches, feeler gages, dial indica
section, with a complete listing at the end of the sec tor set, etc. The inspection work, when performed with
tion. These tools (or their equivalents) are specially the proper methods and tools, is most important.
designed to quickly and safely accomplish the opera The rebuilt engine cannot be expected to perform
tions for which they are intended. They should not be properly if parts worn beyond acceptable limits are
used in operations for which they are not designed. reused.
6A4B-16 4.3L V6 (VIN W)
NOTICE: The following is recom m ended g a s

ket cleaning procedure for General Motors
engine co m p o n en ts. Carefully rem ove all
g a sket material from the part using a plastic
or wood scraper. Use Loctite brand “Chisel
G a sk et R e m o v e r ” (P/N 79040) P erm a tex
brand “G asket Rem over” (P/N 4MA) or equiv
alent. Follow all safety recom m endations and
directions that are on the can.
Do not u se any other m ethod or technique to
rem ove g a sket material from a part. Do not
u s e abrasive p a d s, sa n d paper or pow er
tools to clean g a sket surfaces. These m eth
ods o f cleaning can damage the part. Abra
sive pads also produce a fine grit that the oil
filter cannot rem ove from the oil. This grit is
abrasive and has been known to cause inter
nal engine damage.
NOTICE: If the engine is dam aged internally

and n eeds to be rebuilt, m ake sure all foreign
m aterial is co m p letely flu sh e d o u t o f the
c o o l in g s y s t e m / o i l c o o l e r s y s t e m ( if
equipped). Failure to flush out the debris can
result in damage to the rebuilt engine.
CYLINDER BLOCK
+-► Remove or Disconnect (Figure 21)
1. Oil pressure fitting and sensor.

2. Coolant drain plugs.
3. Oil filter adapter bolts.
4. Oil filter adapter and gasket.
5. Camshaft and balance shaft cup plugs (89).
6. Front oil gallery cup plugs (86).
7. Rear oil gallery plugs (87, 88, and 90).
IJJB Clean
Sealing material from mating surfaces.

Boil cylinder block in caustic solution.
— Flush with clean water or steam.
Cylinder bores.
Threaded holes.
SECTION A-A
Oil galleries and passages.
Scale deposits from coolant passages.
Spray or wipe cylinder bores and machined sur
faces with engine oil. 45. BEARING
47. BALANCE SHAFT
Inspect (Figures 21 and 22) 86. CUP PLUGS
87. PLUG
88. PLUG
1. All expansion plugs for lack of fit or leakage. 89. CUP PLUGS
2. Camshaft lifter bores for deep scratches and 90. PLUG
deposits.
3. Cracks in the block.
V3293
• Cylinder walls.
• Coolant jackets. Figure 21—Cylinder Block Coolant Drain and Oil
• Engine mount bosses. Gallery Plugs
• Main bearing webs.
4.3L V6 (VIN W) 6A4B-17
4. Main bearing bores and caps. 1. Front oil gallery plugs.

• All main bearing bores should be rounded and • Coat plug outside diameter with sealant (GM
uniform in ID at all of the bearing supports. P/N 1052080) or equivalent.
• The area where the main bearing inserts con 2. Rear oil gallery plugs.
tact the main bearing bore should be smooth.
• If a main bearing cap is found to be damaged, Tighten
replace the cap and line bore the block.
5. Cylinder head mounting surface for flatness, using • Plug (87) to 30 N-m (22 lbs. ft.).
a precision straight edge and feeler gage (figure • Plug (88) to 40 N-m (30 lbs. ft.).
22). • Plug (90) to 40 N-m (30 lbs. ft.).
A. Set the straight edge on the sealing surface to 3. Camshaft and balance shaft cup plugs (89) to
be inspected. proper depth.
B. Take the feeler gage and at various locations, • Coat plug outside diameter with sealant (GM
check the gap between the straight edge and P/N 1052080) or equivalent.
the sealing surface. 4. Oil filter adapter, gasket, and bolts.
C. If the gap is found to be greater than 0.05 mm
(0.002 in.) within 152 mm (6 inches) at any $ Tighten
sealing location, the block must be replaced.
D. If the gap is found to be less than 0.05 mm • Bolts to 22 N-m (16 lbs. ft.).
(0.002 in.) within 152 mm (6 inches) at any 5. Coolant drain plugs.
sealing location and a cause for leakage is sus
pected, then the minor irregularities may be $ Tighten
carefully machined from the block.
6. Oil pan, timing cover, and intake manifold mounting • Plugs to 20 N-m (15 lbs. ft.).
surfaces for nicks. Minor irregularities may be 6. Oil pressure fitting and sensor.
cleaned up with a flat file.
$ Tighten
CYLINDER BORE
• Fitting to 11 N-m (97 lbs. in.) plus turn for align
1? Inspect
ment if necessary.
Cylinder bores for scoring or other damage. PISTON AND CONNECTING
Measure ROD ASSEMBLY
NOTICE: The connecting rod, bearing, and
• Cylinder bore taper and out-of-round. Refer to
cap need to be stored together as mating
SECTION 6A.
p a rts, s o th e y m a y b e r e a s s e m b le d in th e
Cylinder Bore Reconditioning sam e wear pattern and balance from which
Refer to SECTION 6A. they were removed.
Install or Connect Refer to SECTION 6A and perform the following:
* 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.
Clean
I? Inspect
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.
UPPER AND LOWER INTAKE

AND EXHAUST MANIFOLDS
Flanges
* Disassemble
I* Inspect
Fuel control and all electrical components from the
upper and lower intake manifolds. Refer to the Camshaft lobes and journals for scratches, pitting,
1995 Driveability, Emissions, and Electrical Diagno scoring, and wear.
sis Manual for the removal of these components.
Measure (Figure 24)
I Clean
Camshaft journal diameters (figure 24). Refer to
“Engine Specifications” for proper diameters.
NOTICE: Do not im m erse the upper or lower
intake manifolds in solvent with electrically CAMSHAFT BEARINGS
operated co m p o n en ts attached or dam age Refer to SECTION 6A for replacement procedures.
m ay occur.
TIM IN G CHAIN AND
NOTICE: Do not clean the manifolds with any SPROCKETS
solution that co n ta in s silicone to p reven t
possible oxygen sen so r contamination. L* Inspect
Sprockets for chipped teeth and wear.

Old pieces of gasket from the gasket surfaces.
— Excessively worn sprockets will rapidly wear a
Excessive carbon buildup in the exhaust passages
new chain.
of the intake manifold.
the intake manifold.
EGR passage of excessive carbon deposits.
J? Inspect (Figure 23)
Manifolds for cracks, broken flanges, and gasket

surface damage.
Alignment (flatness) of exhaust manifold flanges
and upper and lower intake manifold mating sur
faces. Use a straight edge and feeler gage. If the
flanges or mating surfaces do not align, the mani
fold is warped and should be replaced (figure 23).
CAMSHAFT
Important
Whenever the camshaft needs to be replaced, a

new set of lifters must also be installed.
4.3L V6 (VIN W) 6A4B-19
• Timing chain for damage. I? Inspect

— An excessively worn chain will rapidly wear a
new set of sprockets. Front cover for damage, dents, or cracks.
CRANKSHAFT SPROCKET REPLACEMENT
«-4i Remove or Disconnect
4-+ Remove or Disconnect (Figure 25)
Oil seal from the front cover.
Tool Required: • Pry the seal out with a large screw driver.
J 5825-A Crankshaft Gear Remover
• Be careful not to distort the front cover.
1. Crankshaft sprocket using J 5825-A.
2. Key (if damaged). + 4- Install or Connect (Figure 26)
-►4- Instail or Connect (Figure 25)
Tool Required:
Tool Required: J 35468 Front Cover Aligner and Oil Seal
J 5590 Crankshaft Gear Installer Installer
1. Key (if removed). 1. New seal so that the open end of the seal is
2. Crankshaft sprocket using J 5590. toward the inside of the cover. Use adhesive on
seal.
FRONT COVER
A. Support the cover at the seal area.
y| Clean B. Drive the seal into position with J 35468.
2. Lubricate the seal with engine oil before installing
• Old gasket from the gasket surfaces.
the torsional damper.
COOLANT PUMP
y| Clean
• Old gasket from the gasket surface.
NOTICE: Do not im m erse the pum p in sol

vent. The solvent m ay enter the p u m p ’s per
m a n e n tly lu b ric a ted b ea rin g s a n d c a u s e
premature bearing failure.
I? Inspect
Coolant pump shaft for rotation and end play. The

shaft and fan hub should turn straight and smooth
ly. If the hub wobbles or the shaft is noisy or feels
lumpy when turned, replace the pump. If the shaft
end play exceeds 0.015 inch, replace the pump.
Figure 25— Removing Crankshaft Sprocket

6A4B-20 4.3L V6 (VIN W)
* Coolant pump body at the drain (weep) hole. Slight

staining around the weep hole is normal. Only
replace the pump if coolant is dripping from the
weep hole while the engine is running or while the
system is pressurized.
OIL PAN AND ROCKER ARM

COVERS
j| Clean
* Parts in solvent. Remove all sludge and varnish.

* Old gaskets from the gasket surfaces.
Inspect
• Gasket flanges for bending or damage. 66 59

• Rubber grommets and parts on the rocker arm cov
er for deterioration.
• Oil pan for rock damage or cracks.
• Oil pan deflector for lack of fit.
• Drain plug threads for stripping.
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).
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
• 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).
67. Valve Keeper 73. Spring

68. Cap 74. Intake Valve
69. Shield 75. Rotator
70. O-Ring Seal 76. Exhaust Valve
71. Seal '
72. Damper
V0522
Figure 28— Installing Oil Pump Screen Figure 29—Valves and Components
6A4B-22 4.3L V6 (VIN W)
3. Exhaust valve components.

A. Rotator (75).
B. Shield (69).
C. Damper (72).
D. Spring (73).
4. O-ring seals (70).
5. Valves (74 and 76).
• Place the valves (74 and 76) in an organizer
rack so they can be replaced in their original
position at reassembly.
OF CYLINDER HEAD COMPONENTS
IJJI Clean
L* Inspect
Figure 30—Compressing Valve Springs
• 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
• 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 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
THERMOSTAT AND COOLANT TORSIONAL DAMPER

OUTLET
L* Inspect
1. Bolts. hub. Replace as needed. Area of the torsional damper
2. Coolant outlet. hub shaft that contacts the front crankshaft seal for
3. Gasket. roughness or nicks. Replace the damper if this condi
4. Thermostat (with rubber O-ring seal). tion exists. If damper is replaced, new balance weights
of the same size must be installed on the new damper
L* Inspect in the same location as the old damper.

-H- Install or Connect
Py[ Clean
NOTICE: Do not install therm ostat assem bly
without rubber O-ring. Omitting rubber O-ring • Crankshaft with solvent.
m a y re su lt in p o o r en g in e warm -up a n d — Do not scratch the bearing journals.
reduced heater performance. — Remove all sludge from the oil passages with
compressed air.
1. Thermostat (with rubber O-ring seal).
2. New gasket. • Main bearing inserts.
3. Coolant outlet.
— Wipe free of oil with a soft cloth.
4. Bolts.
V Inspect
• Crankshaft for cracks.

$ Tighten
— Use the magnaflux method, if available.
Bolts to 19 N-m (14 lbs. ft.). — Crankpins, main bearing journals, and thrust
surfaces for scoring, nicks, or damage caused
by lack of lubrication.
— Main bearing inserts for scoring or other dam
age.
In general, the lower inserts (except the #1 bearing)
show the greatest wear and distress from fatigue. Upon
inspection, if a lower insert is suitable for reuse, it can
be assumed that the upper insert is also satisfactory. If
a lower insert shows evidence of wear or damage, both
the upper and lower inserts must be replaced.
Measure (Figure 32)
Main bearing and connecting rod journal diameters

(figure 32). Refer to “Engine Specifications,” and
compare dimensions.
Main bearing and connecting rod journals for taper
and out-of-round. Grind or replace the crankshaft if
the journals are tapered more than 0.025 mm
(0.001 inch) or out-of-round more than 0.025 mm
(0.001 inch).
Crankshaft runout.
— Mount the crankshaft in V-blocks or between
centers.
— Use a dial indicator.
— If the main journals are misaligned by more
V0524 than 0.025 mm (0.001 inch), the crankshaft is
bent and must be replaced. The main bearings
Figure 31—Checking Valve Seals must also be replaced at the same time.
6A4B-24 4.3L V6 (VIN W)
CRANKSHAFT REAR
OIL SEAL RETAINER
❖ Disassemble
• Crankshaft rear oil seal if not previously removed.

Insert a screwdriver into the notches provided in
the seal retainer and pry the seal out.
jj| Clean
• All traces of old gasket from the retainer.
]? Inspect
Retainer for cracks, porosity, and damage to the

sealing surfaces.
A. Micrometer
V0573
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.

PRIOR TO ASSEMBLY • If the rear main bearings are replaced, they must
have the proper distance between thrust faces to
The importance of cleanliness during the assembly obtain proper crankshaft end play.
procedure cannot be overstressed. Dirt will cause pre
mature wear of the rebuilt engine. Install or Connect
Lubricate all moving parts lightly with engine oil or
engine assembly lubricant (unless specified otherwise)
during assembly. This will provide initial lubrication NOTICE: For ste p s 4 and 6, refer to “N otice’
when the engine is started. on page 6A4B-1.
1. Upper main bearing inserts to the block.

CRANKSHAFT AND MAIN
BEARING INSTALLATION Important
Main bearings are of the precision insert type and do
• If any undersized bearings are used, they must
not use shims for adjustment. If clearances are exces
be fitted to the proper journals.
sive, both upper and lower bearing inserts will be
2. Crankshaft.
required. Service bearings are available in standard
3. Lower main bearing inserts to the main bearing
size and 0.001-inch, 0.002-inch, 0.009-inch, 0.010-inch,
caps.
and 0.020-inch undersize.
Selective fitting of both rod and main bearing inserts Measure
is necessary in production to obtain close tolerances.
For this reason you may find one-half of a standard
• Main bearing clearance. Refer to SECTION 6A.
insert with one-half of a 0.001-inch undersize insert
• Apply engine oil to the main bearing inserts.
which will decrease the clearance 0.0005 inch from
using a full standard bearing. 4. Main bearing caps (except rear cap) and bolts to
the block.
Some engines may have rear main bearings that are
0.008 inch wider than standard across the thrust faces.
£ Tighten
• The crankshaft on these engines can be identified
by “.008”stamped on the rear counterweight. Main bearing cap bolts to 110 N-m (81 lbs. ft.).
4.3L V6 (VIN W) 6A4B-25
5. Rear main bearing cap. CRANKSHAFT REAR OIL SEAL

• Apply engine oil to the bearing inserts. RETAINER INSTALLATION
6. Rear main bearing cap bolts.
Clean
$ 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).
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)
Tighten Tool Required:

J 35621 Rear Main Seal Installer
Crankshaft rear oil seal.
• Rear main bearing cap bolts to 110 N-m (81 lbs.
A. Lubricate the inner and outer diameter of the
ft.).
seal with engine oil.
B. Install the seal on J 35621.
L® Inspect C. Position J 35621 against the crankshaft. Thread
the attaching screws into the tapped holes in
Crankshaft for binding. Try turning the crankshaft to the crankshaft.
check for binding. If the crankshaft does not turn D. Tighten the screws securely with a screwdriver.
freely, loosen the main bearing cap bolts, one pair This will ensure that the seal is installed
at a time, until the tight bearing is located. Burrs on squarely over the crankshaft.
the bearing cap, foreign matter between the insert E. Turn the handle until it bottoms.
and the block or the bearing cap, or a faulty insert F. Remove J 35621.
could cause a lack of clearance at the bearing.
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)
CAMSHAFT INSTALLATION ^ Tighten
-►+ 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.
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
• Balance shaft retainer bolts (48) to 14 N-m (124

lbs. in.).
4. Balance shaft driven gear (42) and bolt (49).
a Tighten
• Balance shaft driven gear bolt (49) to 20 N m

(15 lbs. ft.) plus an additional turn of 35
Figure 35— Installing Crankshaft Rear Oil Seal degrees using J 36660.
34. NUT
35. STUD
36. KEY
39. BOLT
40. SPROCKET CAMSHAFT
41. CHAIN, TIMING
V2629

4.3L V6 (VIN W) 6A4B-27
Rotate balance shaft (47) by hand to make sure

there is clearance between the balance shaft (47)
and retainer (43). If balance shaft does not rotate
freely, check to be sure retaining ring on front bear
ing is seated on case.
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
balance shaft so the timing mark on the driven
gear (42) points straight down.
Balance shaft drive gear (37) onto camshaft.
Important
• Make sure the timing marks on the balance

shaft drive gear and driven gear line up (figure
39).
Figure 37—Installing Camshaft 6. Balance shaft drive gear bolts.
Tighten
Bolt to 16 N-m (12 lbs. ft.).
Figure 38—Installing Balance Shaft and Components

6A4B-28 4.3L V6 (VIN W)
Gear Timing Marks

St Tighten
Camshaft sprocket bolts (39) and nut (34) to 28

N-m (21 lbs. ft.).

■H“ Install or Connect
1. Front cover gasket to the front cover.

• Use gasket cement to hold the gasket in place.
2. Front cover to the engine.
Tighten
Marks Front cover bolts to 14 N-m (124 lbs. in.).
TIM ING CHAIN AND TORSIONAL DAMPER

SPROCKET INSTALLATION INSTALLATION
-►4- Install or Connect (Figure 40)
Tool Required:
1. Camshaft sprocket and timing chain. J 39046 Harmonic Balancer Remover and
Installer
Important
1. Crankshaft key (if removed).
• Line up the timing marks on the camshaft

NOTICE: The inertial w eig h t se c tio n o f th e
sprocket and crankshaft sprocket (figure 40).
torsional dam per is a ssem b led to the hub
• The number 4 cylinder is at top dead center of with rubber type material. The correct instal
the compression stroke with the timing marks in lation procedures (with the proper tool) m u st
this position (figure 40). b e fo llo w ed or m o v e m e n t o f th e inertial
w eig h t s e c tio n o f th e h u b will d e s tr o y th e
NOTICE: Refer to “N otice” on page 6A4B-1. tuning o f the torsional damper.
2. Stud (item A, figure 41) to the crankshaft. Thread

2. Camshaft sprocket bolts (39) and nut (34). stud fully into the tapped hole in the crankshaft.
4.3L V6 (VIN W) 6A4B-29
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
$ 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.
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 ^
A. Oil Ring Rail Gaps

B. 2nd Compression Ring Gap
G Notch In Piston
D. Oil Ring Spacer Gap
(Tang In Hole Or Slot With Arc)
E. Top Compression Ring Gap B7895
Figure 43— Piston Ring End Gap Locations

6A4B-30 4.3L V6 (VIN W)
V Important
• Each connecting rod and bearing cap should be

Cylinders 1, 3, and 5 are the right bank and 2,
4, and 6 are the left bank (when viewed from
the front). The numbers on the connecting rod
and bearing cap must be on the same side
when installed in the cylinder bore. If a connect
ing rod is ever transposed from one block or
cylinder to another, new connecting rod bear
ings should be fitted and the connecting rod
should be numbered to correspond with the
new cylinder number.
3. Connecting rod cap with bearing insert.
Measure

Clearance SECTION 6A.
E. Place the piston in its matching bore. The con
necting rod bearing tang slots must be on the NOTICE: Refer to “N otice” on page 6A4B-1.
side opposite the camshaft. Using light blows
with a hammer handle, tap the piston down into
4. Connecting rod bolt nuts.
its bore (figure 44). At the same time, from
beneath the engine, guide the connecting rod to
Si Tighten
the crankpin with J 5239 (figure 43). Hold the
ring compressor against the block until all rings
Connecting rod bolt nuts to 27 N-m (20 lbs. ft.).
have entered the cylinder bore.
Connecting rod bolt nuts an additional 70
F. Remove J 5239 from the connecting rod bolts.
V0531
Figure 46—Oil Pan Sealant

4.3L V6 (VIN W) 6A4B-31
© 0 0 0
_ 0 0 ^ 0 ^
B7874
Figure 48—Cylinder Head Bolt Tightening

Sequence

• Apply RTV sealant (GM P/N 12346141) or equiva

lent to the front cover to block joint and to the rear
crankshaft retainer seal to block joint. Apply the
sealant about 25 mm (1 inch) in both directions
from each of the four corners (figure 46).
1. Oil pan gasket (27) to the block.
2. Oil pan (29) to the gasket (27).
3. Oil pan reinforcements (28).

4. Oil pan clips, bolts (83), studs (84), and nuts (82).
27. Gasket 82. Nut
28. Reinforcement 83. Bolt Tighten
29. Oil Pan 84. Stud
V0509
Bolts (83) and Studs (84) to 11 N-m (97 lbs.
Figure 47—Oil Pan and Components in.).
Nuts (82) to 23 N-m (17 lbs. ft.).
Measure
CYLINDER HEAD INSTALLATION
Connecting rod side clearance (figure 45). The
proper clearance is 0.15-0.35 mm (0.015 to 0.046 jg * Clean
inch).
• Gasket surfaces on the block and cylinder head.
OIL PUMP INS' ION
-►<- Install or Connect
1. Head gasket.
1. Oil pump to the engine. • Do not use sealer on composition gaskets.
A. Align the slot in the oil pump shaft with the tang • Place the gasket over the block dowel pins with
on the distributor shaft. the head up.
B. The oil pump should slide easily into place.
C. No gasket is used. 2. Cylinder head. Carefully guide the cylinder head
into place over the dowel pins and gasket.
2. Oil pump to main bearing cap bolt. NOTICE: Refer to “N otice” on page 6A4B-1.
Tighten
3. Cylinder head bolts. Coat threads of the cylinder
Oil pump to main bearing cap bolt to 88 N-m head bolts with sealing compound (GM P/N
(65 lbs. ft.). 1052080) or equivalent and install finger-tight.
6A4B-32 4.3L V6 (VIN W)
19. BOLT 21
20. GUIDE ASSEMBLY
21. NUT
22. BALL
23. ARMS, ROCKER
24. PUSHROD
3706S2910
Tighten 2. Guide assembly.
Previously made mark on guide assembly (20)

Cylinder head bolts in three steps, using the
should be at front of engine.
sequence shown in figure 48.
A. The first sequence to 34 N-m (24 lbs. ft.). Tighten
B. The second sequence to 61 N-m (45 lbs.
ft.).
• Bolts (19) to 16 N-m (12 lbs. ft.).
C. Final torque sequence to 90 N-m (65 lbs.
ft.). 3. Pushrods.
: TRAIN COMPONENT A. Seat the pushrods into the socket of the

hydraulic lifters.
INSTALLATION B. Coat the mating surfaces of the rocker arms
(23) and balls (22) with Engine Oil Supplement
Important
(GM P/N 1052367) or equivalent.
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.).
1. Hydraulic lifters to the block.

4.3L V6 (VIN W) 6A4B-33
Figure 50— Lower Intake Manifold Bolt Tightening Figure 51—Upper Intake Manifold Bolt Tightening
Sequence Sequence
LOWER INTAKE MANIFOLD 1. Upper intake manifold gasket.

2. Upper intake manifold.
INSTALLATION
• Use care not to pinch the injector wires
|-»<-| Install or Connect (Figure 50) between the upper and lower intake manifolds.
3. Upper intake manifold bolts, studs, and support.
1. Gaskets to the cylinder head.
2. RTV to the front and rear sealing surfaces on the Tighten
block. Apply a 5-mm (3/16-inch) bead of RTV (GM a
P/N 1052366) or equivalent to the front and rear of
• Upper intake manifold bolts and studs to 10
the block. Extend the bead 13 mm (1/2 inch) up
N-m (88 lbs. in.) in sequence (figure 51).
each cylinder head to seal and retain the gaskets.
3. Lower intake manifold and lift brackets to the 4. Coil and nuts.
engine.
•Apply sealer, (GM P/N 1052080) or equivalent, to Tighten
the lower intake manifold bolts.
• Nuts to 10 N-m (88 lbs. in.).
5. Plastic cover.
4. Lower intake manifold bolts.
$ Tighten ROCKER ARM COVER

INSTALLATION
• Bolts to 48 N m (35 lbs. ft.) using the tightening
sequence (figure 50). -►4- Install or Connect (Figure 52)
UPPER INTAKE MANIFOLD 1. New gasket.
INSTALLATION 2. Rocker arm cover (2).
|+<-| Install or Connect (Figure 51)

NOTICE: For ste p s 3 and 4, refer to “Notice”
on page 6A4B-1. 3. Rocker arm cover bolts (1) and washers.
6A4B-34 4.3L V6 (VIN W)
Tighten
• Rocker arm cover bolts (1) to 10 N-m (90 lbs.

in.).
EXHAUST MANIFOLD
INSTALLATION
♦«- Install or Connect (Figure 53)
2. Heat shield (60).
3. Exhaust manifold bolts (63), washers (61), and tab
washers (62).
Tighten
A. Bolts on center exhaust tube flange to 35 N-m

Figure 52—Rocker Arm Cover and Components
(26 lbs. ft.).
B. Bolts on front and rear exhaust tube flanges to NOTICE: Refer to “N otice” on page 6A4B-1.
28 N-m (20 lbs. ft.).
C. Bend the tab washers (62) over the heads of all
bolts (63). 3. Bolts.
EGR VALVE INS' ION Tighten

Install or Connect
Bolts to 22 N-m (16 lbs. ft.).
1. New gasket.
2. EGR valve.
Figure 53—Exhaust Manifold Components

4.3L V6 (VIN W) 6A4B-35
FLYWHEEL INSTALLATION ENGINE SET-UP AND TESTING

After overhaul, the engine should be tested before
"►4- Install or Connect installing it in the vehicle.
1. Install oil filter.
2. Fill the crankcase with the proper quantity and
1. Flywheel
grade of engine oil.
NOTICE: Refer to “Notice” on page 6A4B-1. Important
• If a new camshaft or hydraulic lifters were

2. Flywheel bolts. installed, add Engine Oil Supplement (GM P/N
Tighten 3. Fill the cooling system with the proper quantity and
grade of coolant. Refer to SECTION 6B1.
Important
COOLANT PUMP INSTALLATION • Whenever the cooling system is serviced or

+ 4- Install or Connect ant pellets, (GM P/N 3634621) or equivalent,
must be added to the cooling system.
1. Gaskets. • The pellets must be added to the radiator or the
2. Coolant pump. pressurized coolant reservoir.
— Pellets must be crushed prior to installation.
NOTICE: Refer to “Notice” on page 6A4B-1. coolant recovery reservoir. On these systems,
the pellets must be added to the radiator.
3. Coolant pump bolts. sides of pressurized and non-pressurized cool
ant recovery reservoirs. This film is normal.
a Tighten 4. Crank the engine several times. Listen for any
unusual noises or evidence that parts are binding.
• Coolant pump bolts to 40 N-m (30 lbs. ft.). 5. Use the proper on-vehicle Truck Service Manual or
Emission Control Label for specifications on igni
tion timing adjustment.
ENGINE ACCESSORY 6. Start the engine and listen for unusual noises.
INSTALLATION 7. Run the engine speed at about 1000 RPM until the
engine is at operating temperature.
Install the engine accessories (distributor, drive belt 8. Listen for sticking lifters and other unusual noises.
tensioner, oil filter, generator, etc.) as directed in the 9. Check for oil and coolant leaks while the engine is
proper on-vehicle Light Duty Truck Service Manual. running.
Connect all vacuum hoses and electrical equipment the
same way as removed.
6A4B-36 4.3L V6 (VIN W)
SPECIFICATIONS
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
Production
PISTON:
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
1 0.008 (Maximum)
Service Limit 0.065
PISTON PIN:
Diameter 0.9270-0.9273
EXHAUST MANIFOLD:
INLET MANIFOLD:
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
#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 Runout 0.001 (Maximum)
Diameter 2.2487-2.2497
Production 0.0002
Taper
Crankpin Service Limit 0.001 (Maximum)
Clearance Service Limit 0.0030
CAMSHAFT:
Lobe Intake 0.288
0.001-0.009
VALVE SYSTEM:
Lifter Hydraulic
Intake
Valve Lash Torque Rocker Arm Nut to 27 N m (20 lbs. ft.)
Exhaust
Intake 0.035-0.060
Seat Width
Exhaust 0.062-0.093
Intake 0.0011-0.0027
Production
Service
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
Damper Approx # of Coils 4
Intake 0.432
Valve Lift
Exhaust 0.441
T3050
6A4B-38 4.3L V6 (VIN W)
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 —
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
3. J 35468 /. l. J «■ '— AiUHt g f t

J 21882
12 . 1
4. J 8080 J 5825-A
13.
5. J 8037 14. J 5590
6. J 5239
15. J 35621
16. J 8092
J 23738-A
7.
17. J 36996
8.
1. HARMONIC BALANCER REMOVER AND INSTALLER 18. J 36660

2. VALVE SPRING COMPRESSOR
3. FRONT COVER ALIGNER AND OIL SEAL INSTALLER
4. MAIN BEARING SHELL REMOVER AND INSTALLER
5. PISTON RING COMPRESSOR
6. CONNECTING ROD BOLT GUIDE SET
7. VALVE STEM SEAL TESTER
8. BALANCE SHAFT BEARING SERVICE KIT
9. DIAL INDICATOR SET 14. CRANKSHAFT GEAR INSTALLER
10. NEEDLE BEARING PULLER 15. REAR MAIN SEAL INSTALLER
11. RIDGE REAMER 16. DRIVER HANDLE
12. OIL SUCTION PIPE INSTALLER 17. BALANCE SHAFT INSTALLER
13. CRANKSHAFT GEAR REMOVER 18. TORQUE/ANGLE METER
3706r0535
.
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
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
• 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
Timing Chain and Camshaft Sprocket Removal.........................................................................................6A5B-17
Camshaft Removal............................................................................................................................................. 6A5B-17
Piston and Connecting Rod Removal........................................................................................................... 6A5B-19
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
Front C over..........................................................................................................................................................6A5B-30
Coolant Pum p..................................................................................................................................................... 6A5B-31
Oil Pan and Rocker Arm C overs................................................................................................................... 6A5B-31
Oil Pump.............................................................................. .................................................................................6A5B-31
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
Torsional Dam per............................................................................................................................................... 6A5B-37
Crankshaft Rear Oil Seal Retainer (5.0L and 5.7L Engines)................................................................... 6A5B-38
Assembly of the Engine....................................................................................................................................... 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
Piston and Connecting Rod Installation...................................................................................................... 6A5B-42
Connecting Rod Bearing Selection............................................................................................................6A5B-42
Oil Pump 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
Exhaust Manifold Installation...........................................................................................................................6A5B-50
Flywheel Installation...........................................................................................................................................6A5B-51
Engine Set-Up and Testing.............................................................................................................................. 6A5B-53
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
Figure 1—Lubrication Diagram (5.0L and 5.7L Engines)

6A5B-4 V8 ENGINES
3706S3004
Figure 2—Lubrication Diagram (5.0L and 5.7L Engines)

V8 ENGINES 6A5B-5
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
Figure 3— Lubrication Diagram (7.4L Engines)
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
Figure 4— Cylinder Block and Components (5.0L and 5.7L Engines)

V8 ENGINES 6A5B-7
10 C OOLANT P U M P 148 NUT

11 C OOLANT P U M P GASKET 149 CONNECTING ROD BEA R IN G CAP
12 C OOLANT P U M P BO LT 150 CONNECTING ROD BEARING
13 P LU G 151 PISTON P IN
71 OIL PAN 152 CONNECTING ROD
72 B O LT 153 PISTON
73 NUT 154 PISTON RINGS
74 OIL PAN GASKET 155 CONNECTING ROD B O LT
75 R E IN FO R C E M E N T 156 EXP AN SIO N CUP P LU G
76 OIL PAN D E FLE C TO R 157 P LU G
77 OIL P U M P B O LT 158 DRAIN P LU G
79 OIL PAN D E FLE C TO R 159 DOW EL PIN
89 C R A N K S H A F T FRONT O IL SEAL 160 LO C K W ASHER
90 FR O N T COVER GASKET 161 C LU TC H COVER AND P R E S S U R E PLA TE B O LT
91 FR O N T COVER 163 B O LT
93 F R O N T COVER BO LT 164 C LU TC H FO R K B A L L STUD
99 PIN 165 C LU TC H HOUSING
100 CAMSHAFT S P R O C K E T B O LT 166 C LU TC H P R E S S U R E P LATE COVER
101 CAMSHAFT S P R O C K E T 167 C LU TC H P ILO T BEARING
102 TIMING CHAIN 168 FLY W H E E L DOWER PIN
110 FLY W H E E L 169 OIL PAN DRAIN P LU G
111 F LY W H E E L BO LT 170 GASKET
118 GROOVE PIN 171 OIL PAN STUD
119 TO RSIO N AL DAM PER 172 C LA M P (AUTOM ATIC TR A N S M IS SIO N O N L Y )
120 REAR SEAL RETAINER GASKET 173 S P R IN G PIN
121 C R AN K S H AFT REAR SEAL RETAINER 174 C LU TC H DRIVEN PLATE
122 REAR SEAL RETAINER SCREW 175 P LU G
123 REAR SEAL RETAINER NUT 176 E XP AN SIO N CUP P LU G
124 REAR SEAL RETAINER STUD 178 OIL P U M P DRIVE SHAFT
130 C R AN K S H AFT 179 RETAINER
132 REAR MAIN BEARING CAP 180 OIL P U M P
133 MAIN BEAR IN G CAP 182 OIL P U M P COVER
134 MAIN BEAR IN G CAP B O LT 183 OIL P R E S S U R E R EGULATOR VALVE
135 LOW ER MAIN BEA R IN G INSERT 184 REGULATOR VALVE S PR IN G
136 UPPER MAIN BEAR IN G INSERT 185 S PR IN G STOP RETAINING P IN
137 MAIN BEAR IN G CAP STUD 187 P IC K - U P SC RE E N AND P IP E
138 OIL L E V E L INDICATOR 190 PIN
139 BO LT 191 REGULATOR VALVE S PR IN G STOP P LU G
140 OIL L E V E L INDICATOR TU BE 192 BO LT
141 BO LT 214 CRANKSHAFT SPROCKET
142 FUEL P U M P O P E N IN G COVER 215 W O O D R U FF K E Y
143 FUEL P U M P O P E N IN G COVER GASKET 216 CAMSHAFT
144 ENGINE B LO C K 217 PIN
145 FITTING 218 CAM SHAFT BEAR IN G S
146 O IL P R E S S U R E AND F U E L P U M P SWITCH S EN SO R 219 OIL P R E S S U R E P LU G
147 P LU G 220 GROOVE PIN
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
Figure 8—Cylinder Block and Components (7.4L Engine)

V8 ENGINES 6A5B-11
10. Coolant Pump 184. Oil Pressure Regulator Valve Spring

11. Coolant Pump Gasket 185. Spring Retaining Pin
12. Coolant Pump Bolt 187. Pick-up Screen and Pipe
13. Coolant Pump Plug 190. Gasket
74. Oil Pan Gasket 191. Piston Rings
75. Oil Pan Bolt 192. Piston
76. Oil Pan 193. Connecting Rod Bolt
77. Oil Pump Bolt 194. Connecting Rod
90. Front Cover Gasket 195. Connecting Rod Bearing
91. Front Cover 196. Connecting Rod Bearing Cap
93. Front Cover Bolt 197. Connecting Rod Nut
100. Camshaft Sprocket Bolt 198. Engine Block
101. Camshaft Sprocket 200. Engine Balance Groove Pin
102. Timing Chain 201. Oil Pan Drain Plug
110. Flywheel 202. Crankshaft Sprocket
111. Flywheel Bolt 203. Washer
120. Torsional Damper 204. Spring Lock Washer
130. Crankshaft 205. Bolt "
132. Rear Main Bearing Cap 206. Engine Balance Groove Pin
133. Main Bearing Cap 207. Camshaft Bearings
134. Main Bearing Cap Bolt 208. Woodruff Key
135. Lower Main Bearing Insert 209. Camshaft
136. Upper Main Bearing Insert 210. Drain Plug
177. Regulator Valve Spring Retainer 214. Nipple
178. Oil Pump Driveshaft 215. Clamp
179. Connector 216. Hose
180. Oil Pump Body 217. Clamp
182. Oil Pump Cover 218. Nipple
183. Oil Pressure Regulator Valve 219. Piston Pin
V1205
Figure 9—Cylinder Block and Components (7.4L Engine) - Legend

6A5B-12 V8 ENGINES
3706S3006
Figure 10—Cylinder Head, Manifolds, and Components (7.4L Engine)

V8 ENGINES 6A5B-13
1 E XH AU ST M A N IFO LD 260 P U S H R O D GUIDE

4 B O L T /S T U D 30 1 STUD
6 HEAT S H IE L D A S S E M B LY 302 COOLANT O U TLET
21 INTAKE M A N IFO LD 303 THERMOSTAT
22 INTAKE M A N IFO LD GASKET 304 GASKET
23 INTAKE M A N IFO LD SEA L 309 R O C KER COVER GASKET

30 R O C K ER COVER B O LT 311 C OOLANT TEM P E R ATU R E S EN SO R
31 SUPPO RT, SPARK P LU G WIRES 312 SPARK P LU G
32 RO C K ER ARM COVER 313 ENGINE L IF T B R AC K E T
40 R O C K ER ARM B O L T 314 S PR IN G LO C K W ASHER

41 R O C K ER ARM B A L L 315 B O LT
42 R O C K ER ARM 316 STUD

44 H Y D R A U LIC LIF TE R 317 B O LT
45 C Y LIN D ER HEAD B O LT 318 ENGINE L IF T B R AC K E T
46 C Y LIN D ER HEAD 319 STUD

47 C Y LIN D ER HEAD GASKET 320 EGR ELE C TR O N IC VACUUM
251 VALVE STEM K E Y REGULATOR S 0 L E N S 0 ID VALVE B R AC KET
253 VALVE S PR IN G CAP 32 1 NUT
255 VALVE S PR IN G ROTATOR 322 C LA M P
256 VALVE S PR IN G 323 HOSE

257 VALVE STEM OIL SEAL 324 C LA M P
259 INTAKE VALVE 325 N IP P L E
3706S3006
Figure 11—Cylinder Head, Manifolds, and Components (7.4L Engine) - Legend

It is beyond the scope of this section to detail the
TOOLS AND SHOP EQUIPMENT many different accessory installations. Refer to the
A clean, well lit work area should be available. Other
proper on-vehicle Truck Service Manual for this infor
necessary equipment includes: a suitable parts cleaning
mation.
tank, compressed air supply, trays to keep parts and
Diagrams of emission and vacuum hose routings, wir
ing harness routing, accessory drive belt layout, etc.,
An approved engine repair stand will help prevent per
should be made before removing accessories.
sonal injury or damage to engine components.
Special tools are illustrated throughout this section
and listed at its end. These tools (or their equivalents)
CLEANING
are specially designed to quickly and safely accomplish Remove the engine accessories before cleaning to
the operations for which they are intended. The use of provide better access to the engine’s exterior surfaces.
these tools will also minimize possible damage to After removing the TBI unit, distributor, etc., cover the
engine components. openings with tape to prevent the entry of coolant, sol
Some precision measuring tools are required for vent, and dirt.
inspection of certain critical components. Torque Methods used to clean the engine will depend on
wrenches will be necessary for correct assembly of var what equipment is available. Steam cleaning, pressure
ious parts. washing, or solvent cleaning are some acceptable
methods. Allow the engine to dry before beginning the
ACCESSORY REMOVAL work.
This manual assumes that the engine accessories It is important that the engine be as clean as possible
have been removed. These accessories may include to prevent dirt from entering critical areas during disas
one or more of the following: sembly.
• Power Steering Pump
• Distributor DRAINING THE ENGINE
• AIR System Pump
• Generator ++ Remove or Disconnect
• Air Conditioning Compressor
• EGR Valve and Emission Control Equipment 1. Oil pan drain plug. Allow the oil pan to drain.
• Cooling Fan 2. Oil filter.
6A5B-14 V8 ENGINES
1. Exhaust Manifold
2. Washer
3. Lock
4. Bolt/Stud
6. Spark Plug Wire Heat Shield
Figure 12—Exhaust Manifold (5.0L and 5.7L Engines)
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).

NOTICE: For ste p s 1 and 2, refer to “N otice’
on page 6A5B-1. <--► Remove or Disconnect (Figures 16 and 17)
1. Oil pan drain plug. 1. Bolts (19) and studs (20).
2. Intake manifold (21).
Tighten
• Pull the intake manifold up.
•O il pan drain plug to 22 N-m (16 lbs. ft.)
5.0L75.7L Engines).
NOTICE: Do not attem pt to loosen the mani
• Oil pan drain plug to 28 N-m (20 lbs. ft.) (7.4L
fold b y prying under the ga sket surface with
Engines).
any tool.
2. Block drain plugs.
Tighten 3. Gaskets (22).

$ 4. Seals (23) (7.4L engines).
•B lo ck drain plugs to 22 N-m (16 lbs. ft.)
(5.0L/5.7L Engines). ROCKER ARM COVER REMOVAL
• Block drain plugs to 12 N-m (112 lbs. in.) (7.4L
Engine). +-► Remove or Disconnect (Figures 18 and 19)
EXHAUST MANIFOLD REMOVAL 1. Bolts (30 or 36).

2. Rocker arm covers (32). If the rocker arm cover
Remove or Disconnect (Figures 12 and 13) sticks to the cylinder head, try bumping the end of
the cover with a rubber mallet. If the cover will not
1. Oil dipstick tube. come loose, carefully pry until loose. DO NOT DIS
TORT THE SEALING FLANGE.
• On 5.0L and 5.7L engines, bend back the tab
3. Gaskets (34).
washers (3).
2. Bolts and studs (4). VALVE TRAIN COMPONENT
3. Tab washers (3) and washers (2).
4. Heat shields (6). REMOVAL
5. Exhaust manifold (1). Use care not to damage the
AIR system injection tubes (if used). ++ Remove or Disconnect (Figures 20 through
26)
Tools Required:
Remove or Disconnect (Figures 14 and 15) J 3049-A Valve Lifter Remover (Plier Type)
J 9290-01 Valve Lifter Remover (Slide Hammer
1. Bolts (12). Type)
V8 ENGINES 6A5B-15
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
Figure 13—Exhaust Manifold (7.4L Engines)

1. Nuts (40) (5.0L and 5.7L engines) or bolts (40)
(7.4L engines), balls (41), rocker arms (42), and
pushrods (43 or 210).
• On 7.4L engines, the exhaust valve pushrods
are longer than the intake valve pushrods.
• Every effort should be made to ensure that
these mating parts are installed in their original
locations during assembly. A simple valve train
component organizer rack can be made from a
piece of wood, as shown in figure 24.
10. Coolant Pump 12. Bolt

11. Gasket 13. Plug F9349
Figure 15—Coolant Pump (7.4L Engines)
2. Hydraulic lifters (44 or 209).

• Remove the lifters one at a time using a mag
net. Place the lifters in the organizer rack, or
tag them in some way to ensure they can be
returned to the valve lifter bore from which they
were removed.
• Some lifters may be stuck in their bores due to
gum or varnish deposits. These lifters can be
removed using either J 3049-A (figure 25) or
J 9290-01 (figure 26).
6A5B-16 V8 ENGINES
Figure 16—intake Manifold (5.0L and 5.7L Engines)
CYLINDER HEAD REMOVAL OIL PAN REMOVAL

4* + Remove or Disconnect (Figures 20 through Remove or Disconnect (Figures 28, 29, and
23) 30)
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).
TORSIONAL DAMPER REMOVAL OIL PUMP REMOVAL

4 -* Remove or Disconnect (Figure 27) Remove or Disconnect (Figures 28 and 30)
Tool Required: 1. Bolts.

J 39046 Torsional Damper Puller and Installer 2. Oil pump, with drive shaft and connector.
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
Figure 17—Intake Manifold (7.4L Engines)
FRONT COVER REMOVAL

4-+ Remove or Disconnect (Figure 31)
1. Bolts (93).
2. Front cover (91).
3. Gasket (90).
TIM IN G CHAIN AND CAMSHAFT

SPROCKET REMOVAL
4~¥ Remove or Disconnect (Figure 32)
• Tinning chain free play. If the chain can be moved

back and forth in excess of 16 mm (5/8 inch),
make a note that the timing chain should be
replaced during assembly (figure 32).
1. Bolts (100).
2. Camshaft sprocket (101) and timing chain (102)
together.
CAMSHAFT REMOVAL
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
Figure 19—Rocker Arm Cover (7.4L Engines)
46. HEAD, CYLINDER

47. GASKET, CYLINDER HEAD
51. BOLT, CYLINDER HEAD
144. BLOCK, ENGINE
V2880
Figure 20—Cylinder Head (5.0L and 5.7L Engines)

V8 ENGINES 6A5B-19

ROD REMOVAL
Tool Required:
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.
40. NUT, ROCKER ARM

41. BALL, ROCKER ARM
42. ARM, ROCKER
46. HEAD, CYLINDER
144. BLOCK, ENGINE
209. LIFTER, VALVE
210. PUSHROD
V2881
Figure 22—Valve Train Components (5.0L and 5o7L Engines)

6A5B-20 V8 ENGINES
40. Bolt
41. Ball
42. Rocker Arm
43. Pushrod
44. Hydraulic Lifter
46. Cylinder Head
260. Pushrod Guide
F9325
Figure 23—Valve Train Components (7.4L Engines)
-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
D. Remove the connecting rod cap.

A. 22 mm (7/a-inch) N r E. Install J 5239 onto the connecting rod bolts.
B. 55 mm (21/4-inch) Use of the specified guide set will prevent the
C. 40 mm (11/2-inch) connecting rod from scratching the bore or
D. 10 mm (3/s-inch) drill, 25 mm (1-inch) deep crankshaft journal during the removal process.
E. 22 mm (7/s-inch) drill, 25 mm (1-inch) deep The tool will also prevent the rod bearing half
F. Material: 50 mm x 200 mm (2 x 8-inch) lumber from falling out of the connecting rod during
removal.
B5267
3. Connecting rod and piston from the block.
Figure 24—Valve Train Component Organizer
A. Push on the guide rod (item A, figure 35) to
push the piston and connecting rod out.
V8 ENGINES 6A5B-21
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).
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.
1. Screws (80) and nuts (81).

2. Seal retainer (82).
3. Gasket (84).
6A5B-22 V8 ENGINES
70. Oil Pump

76. Nut
77. Bolt
79. Oil Pan Baffle
F9365
Figure 29—Oil Pan Deflector (5.0L and 5.7L

Engines)
A. Sealing Compound
74. Gasket
75. Bolt
76. Oil Pan
F9331
Figure 30—Oil Pan (7.4L Engines)
Figure 31— Front Cover

V8 ENGINES 6A5B-23
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 36—Flywheel (5.0L and 5.7L Engines)
80. SCREW, SEAL RETAINER

81. NUT, SEAL RETAINER
82. RETAINER, SEAL
83. STUD, SEAL RETAINER
84. GASKET, SEAL RETAINER
114. BLOCK, ENGINE
V2976
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
Figure 39—Crankshaft and Components (7.4L

Engines)

A solvent tank large enough to hold the larger engine NOTICE: The following is recom m ended g a s
parts will be needed along with various bristle brushes ket cleaning procedure for General Motors
and a gasket scraper. A source of compressed air will en g in e co m p o n en ts. Carefully rem ove all
be helpful in the cleaning operations. g a sket material from the part using a plastic
Precision measuring tools will be required for the or wood scraper. Use Loctite brand “Chisel
inspection procedure. These include: micrometers, cyl G asket R em over” (P/N 4MA) or equivalent.
inder bore gage, feeler gages, dial indicator set, etc. Do not u se any other m ethod or technique to
The inspection work, performed with the proper meth
rem ove g a sket material from a part. Do not
u s e abrasive p a d s, s a n d p a p er or p o w er
ods and tools, is most important. The rebuilt engine
tools to clean g a sket surfaces. These m eth
cannot be expected to perform properly if parts worn
o ds o f cleaning can damage the part. Abra
beyond acceptable limits are reused.
sive pads also produce a fine grit that the oil
filter cannot rem ove from the oil. This grit is
abrasive and has been known to cause inter
nal engine damage.
6A5B-26 V8 ENGINES
147. PLUG, OIL GALLERY HOLE

V2883
Figure 40—Engine Block Oil Gallery Hole Plugs (5.0L and 5.7L Engines)
NOTICE: If the engine is dam aged internally

and needs to be rebuilt, m ake sure all foreign
m aterial is co m p letely flu sh e d o u t o f the
cooling system . Vehicles equipped with an
oil cooler should also be flushed out. Failure
to rid the oil or cooling system o f debris can
result in engine dam age to the rebuilt engine.
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
V2888
Figure 42—Engine Block Oil Gallery Hole and Coolant Drain Hole Plugs (7.4L Engines)
m Measure (Figure 43)
Head gasket surface distortion. Use a straight edge

and feeler gage to check for flatness of the milled
surface at the top of the cylinder block. The surface
must be flat (within 0.10 mm {0.004 inch}) to
ensure proper head gasket sealing.
Figure 43—Checking the Block Gasket Surface
• All main bearing bores should be round and

uniform in inside diameter (ID) at all bearing
supports.
• The area where the main bearing inserts con
tact the main bearing bore should be smooth.
• If a main bearing cap is damaged and requires
replacement, replace it as outlined later.
Figure 44—Piston Diameter Measurement

6A5B-28 V8 ENGINES
CYLINDER BORES
I? Inspect
Cylinder bores for scoring and other damage.
Measure
• Cylinder out of round and taper. Refer to SECTION

6A.
Cylinder Bore Reconditioning

Refer to SECTION 6A.
PISTON AND CONNECTING ROD

B0412
ASSEMBLIES
Figure 45— Measuring Piston Diameter For disassembly, cleaning, inspection, and assembly
of these components, refer to SECTION 6A.
MAIN BEARING CAP REPLACEMENT
tjj Measure (Figures 44 and 45)
++ Install or Connect
• Piston pin diameter and pin to piston clearance.
1. New main bearing cap. The arrow on the main • Piston to bore clearance and fit pistons as outlined.
bearing cap faces the front of the engine (opposite
the flywheel). PISTON SELECTION
1. Check the used piston to cylinder bore clearance,
as follows:
2. Main bearing cap bolts. A. Cylinder bore diameter. Use a telescoping bore
gage, located 65 mm (2 1/2 inches) below the
£ Tighten top of the cylinder bore (figure 44).
B. Piston diameter. Measure the skirt at a right
Bolts to “Specifications.” angle to the piston pin hole (figure 45).
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
Each connecting rod and bearing cap should be

Cylinders 1, 3, 5, and 7 are the right bank and
2, 4, 6, and 8 are the left bank (when viewed
from the front of the engine). The numbers on
the connecting rod and bearing cap must be on
the same side when installed in the cylinder
bore. If a connecting rod is ever transposed
from one block or cylinder to another, new con
necting rod bearings should be fitted and the
connecting rod should be numbered to corre
spond with the new cylinder number. On 7.4L
engines the rod is not symmetrical and the out
Flanges side always faces out.
V8 ENGINES 6A5B-29
Alignment of exhaust manifold flanges. Use a

straight edge and feeler gage (figure 46). If the
flanges do not align, the manifold is warped and
should be replaced or resurfaced.
AIR system injection tubes for damage. Replace as
needed.
CAMSHAFT
Important
Do not attempt to repair the camshaft. Replace it if

damaged.
Figure 47—Measuring Camshaft Run-Out Whenever the camshaft needs to be replaced, a
new set of valve lifters must also be installed.
I? Inspect
Camshaft distributor gear teeth.

Bearing surfaces and lobes for wear.
Sprocket.
Keyway and threads.
— Galling
— Gouges
— Overheating (Discoloration)
|j| Measure (Figures 47 and 48)
Tool Required:
• 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.”
MANIFOLD CAMSHAFT BEARINGS

| Clean Refer to SECTION 6A for replacement procedures.
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
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
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.
* Assemble (Figures 49 and 50) * Disassemble
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
Crankshaft front seal. Use J 35468 (5.0L and 5.7L

engines) or J 22102 (7.4L engines) (figure 51). The J 22102
open end of the seal must be facing the inside of
the front cover.
Lightly coat the seal lips with grease.
COOLANT PUMP
Clean
All gasket mating surfaces. Be sure old gasket

material is removed and free of oil or other foreign
materials.
NOTICE: Do not im m erse the pum p in sol

v e n t The solven t m ay enter the p u m p ’s per F9000
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
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
gears, cover, and body are not serviced separately.

If the parts are damaged or worn, replace the
178 187 entire oil pump assembly.
Pressure relief valve (183) for fit. The regulator
valve should slide freely in its bore without sticking
or binding (figures 52 and 53).
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
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
• Screws (186) to 12 N-m (106 lbs. in.).

• Turn the driveshaft by hand to check for smooth
Figure 53—Oil Pump Components (7.4L Engines) operation.
Inspect NOTICE: Be careful o f twisting, shearing, or

collapsing the pipe while installing it in the
• Pump body (180) and cover (182) for cracks or pum p.
other damage.
• Gears (181 and 188) for wear. 7. Pickup screen and pipe (187) (if removed) (figure
•Drive gear and shaft (181) for lack of fit in the 54).
pump body (180). A. If the pickup screen and pipe assembly was
• Inside of the cover (182) for wear that would permit removed, it should be replaced with a new part.
Loss of press fit condition could result in an air
oil to leak past the ends of the gears. The pump
leak and loss of oil pressure.
B. Mount the oil pump in a soft jawed vise.
Figure 54— Installing the Oil Pump Pickup Tube and Screen (5.0L and 5.7L Engines)
V8 ENGINES 6A5B-33
C. Apply sealer to the end of the pipe.

D. Tap the pickup screen and pipe into place,
using J 21882 (5.0L and 5.7L engines), and a
hammer.
E. The pump screen must be parallel with the bot
tom of the oil pan. The screen of the oil pump
is about 1/4 inch from the bottom of the pan.
8. Oil pump driveshaft (178) and connector (179).

PUSHRODS, ROCKER ARMS, BALLS, AND NUTS
Pyj Clean
• Parts in solvent. Blow dry with compressed air.

• Make sure the oil passages in the pushrods are
clear.
• Rocker arms and balls at their mating surfaces.
These surfaces should be smooth and free from
scoring or other damage.
• Rocker arm areas that contact the valve stems and
the sockets that contact the pushrods. These areas
should be smooth and free of damage and wear.
• Rocker arm nuts or bolts.
— The 5.0L and 5.7L engines use prevailing
torque nuts. At least 6.2 N-m (55 lbs. in.) of
torque should be required to thread the nuts
onto the rocker arm studs. If not, it is possible
that the nut(s) could back off during engine
operation causing a loss of lash and valve train
noise.
— The 7.4L engine uses a bolt to retain the rocker
arm, ball, and pushrod guide to the cylinder
head. Inspect rocker arm bolts for signs of
cracking at the bolt shoulder. Replace if neces
sary.
• Check pushrods for bending. Roll the pushrod on a
flat surface to determine if it is bent. Replace if
necessary.
• Check ends of the pushrods for scoring or rough
ness.
HYDRAULIC LIFTERS
Refer to SECTION 6A.
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 ^
40 B O LT 1. Place J 5802-01 over the stud to be removed.

41 BALL Install a nut and flat washer. Remove the stud by
42 ROC KER ARM turning the nut (figure 58).
46 C Y LIN D ER HEAD 2. Ream the hole to the proper size for the replace
47 GASKET ment oversize stud. Use J 5715 for 0.0762 mm
251 V ALVE K E E P E R S (0.003-inch) oversize studs; J 6036 for 0.3302 mm
253 CAP
(0.013-inch) oversize studs (figure 59).
3. Coat lower end (press-fit area) of stud with hypoid
254 ROTATOR
axle lubricant. Drive the stud into place with a ham
256 S PR IN G
mer and J 6880. Stud is installed to proper depth
257 SEAL
when the tool bottoms on the cylinder head (figure
258 EXH AUST VALVE
60).
259 INTAKE VALVE
259 INTAKE VALVE ASSEMBLY (5.0L AND 5.7L ENGINES)
260 P U S H R O D GUIDE
3706S3011
Tools Required:
Figure 56—Cylinder Head and Components (7.4L J 23738-A Valve Seal Leak Detector
Engines) 1. Valves (258 and 259).
• Lubricate the valve stems with engine oil.
CLEANING AND INSPECTION • Insert the valves into the proper guides.
2. Seals (257). Install the seals over the valve stems
and seat them against the head.
Measure
3. Springs with dampers (256).
4. Shields (255).
• Valve stem clearance.
5. Caps (253) (intake valves only).
• Valve spring tension and free length.
6. Rotators (254) (intake and exhaust valves on 5.7L
Other information outlined includes:
H.D.and exhaust valve only on 5.0L and 5.7L
• Valve and seat grinding.
engines).
• Valve guide reaming.
• Compress the valve spring, using J 8062 (figure
ROCKER ARM STUD REPLACEMENT (5.0L AND 55). Compress the spring enough so the lower
5.7L ENGINES) valve stem groove can be clearly seen.
Tools Required: 7. O-ring seals (252) and valve keepers (251).
J 5802-01 Stud Remover A. Push a new O-ring seal onto the valve stem.
J 5715 Reamer {0.0762 mm (0.003-inch) over The seal must be installed on the stem’s lower
size} or groove. Make sure the seal is flat and not twist
J 6036 Reamer {0.3302 mm (0.013-inch) over ed.
size} B. Apply a small amount of grease to the area of
J 6880 Stud Installer the upper valve stem groove. Assemble the two
Rocker arm studs that have damaged threads or are valve keepers using the grease to hold the keys
loose in cylinder heads should be replaced. New studs in place. Make sure the keepers seat properly
are available in 0.003-inch and 0.013-inch oversize. in the groove.
V8 ENGINES 6A5B-35
A. Nut
B. Flat Washer L0620
Figure 58— Removing the Rocker Arm Stud (5.0L

and 5.7L Engines)
Figure 60— Installing the Rocker Arm Stud (5.0L

and 5.7L Engines)
J 23738-A
(5.0L and 5.7L Engines)
C. Release the compressor tool. Make sure the

valve keepers stay in place.
D. Repeat the preceding steps on the remaining
valves.
E. Check each seal, using J 23738-A (figure 61).
Place the adapter cup over the shield. Operate
the vacuum pump. Observe the vacuum pump L0617
gage. No air should be able to leak past the
Figure 61—Checking the Valve Seal (5.0L and 5.7L
seal. If the seal will not hold a vacuum, it may Engines)
have been damaged or improperly installed.
2. Measure from the valve shim or spring seat to
Measure (Figures 62 and 63) the top of the shield (255) (figure 63).
3. If this measurement exceeds the amount given
Valve spring installed height of each valve spring in “Engine Specifications,” install valve spring
as follows: seat shims of sufficient thickness (between the
spring and cylinder head) to give the desired
1. Use a narrow, thin scale. A cutaway scale (fig measurement. NEVER shim the spring so as to
ure 62) may be helpful. give an installed height under the specified
amount.
6A5B-36 V8 ENGINES
" t i t■' t t r " l'" r |" T " T"i"r[," r

i i 3 4 :
A. Grind out this portion.

B5248
Figure 62—Cutaway Scale

ASSEMBLY (7.4L ENGINES)
3706S3010
* Assemble (Figures 56 and 57)
Tool Required: Figure 63—Measuring Valve Spring Installed Height

1. Valves (258 and 259).
A. Lubricate the valve stems with engine oil.
B. Insert the valve into the proper guide.
2. Rotators (254).
3. Seals (257).
A. Lubricate the seals with engine oil.
B. Push the seals into place.
4. Valve springs with dampers (256).
5. Caps (253).
6. Valve keepers (251).
A. Compress the valve spring using J 8062 (figure
57). Compress the spring until the valve stem
groove can be seen.
B. Apply a small amount of grease to the area of
the valve stem groove.
C. Assemble the valve keepers, using the grease
to hold the keys in place. Make sure the keep
ers seat properly in the groove.
D. Release the compressor tools. Make sure the
E. Repeat this procedure on the remaining valves.
• Valve spring installed height of each valve spring.

1. Use a narrow, thin scale. A cutaway scale (fig
ure 62) may be helpful.
2. Measure from the spring seat to the top of the
valve spring (figure 63).
3. If this measurement exceeds the amount given
in “Engine Specifications,” install valve spring
seat shims of sufficient thickness (between the
spring and cylinder head) to give the desired
measurement. NEVER shim the spring so as to
give an installed height under the specified
amount.
THERMOSTAT AND COOLANT

OUTLET
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

S2jj| Clean
• Crankshaft with solvent.

• Blow all sludge from the oil passages with com
pressed air.
• Main bearing inserts. Wipe free of oil with a soft
cloth.
• Seal running surfaces with a non-abrasive cleaner.
I? Inspect
20. Stud • Crankshaft for cracks. Use the magnaflux method,

21. Coolant Outlet if available.
23. Thermostat • Crankpins, main bearing journals, and thrust sur
25. Intake Manifold faces for scoring, nicks, or damage caused by lack
F9551 of lubrication.
• Main bearing inserts for scoring or other damage.
Figure 65—Thermostat and Components (7.4L
Engines) In general, the lower inserts (except the #1 bearing)
show greater wear and the most distress from fatigue.
3. Thermostat (23). If, upon inspection, the lower insert is suitable for use, it
can be assumed that the upper insert is also satisfacto
Inspect ry. If the lower insert shows evidence of wear or dam
age, both the upper and lower inserts must be replaced.
Thermostat Check
Refer to SECTION 6B1 in the proper on-vehicle Light Main bearing and connecting rod journal diameters
Duty Truck Service Manual. (figure 66). Compare with “Engine Specifications.”
Grind or replace the crankshaft if necessary.
■44- Install or Connect (Figures 64 and 65) Main bearing and connecting rod journals for taper
and out-of-round (figure 66). If the journals are
tapered or out-of-round more than 0.0254 mm
NOTICE: Do not install therm ostat assem bly (0.001 inch), grind or replace the crankshaft.
without rubber O-ring. Omitting rubber O-ring Crankshaft run-out (figure 67).
m ay re su lt in p o o r en g in e warm -up a n d A. Mount the crankshaft in V-blocks on main jour
reduced heater performance. nals 1 and 5.
B. Use a dial indicator to measure the crankshaft
runout, as shown in figure 67.
1. Thermostat (23) with rubber O-ring. C. If the main journals are misaligned, the crank
2. Coolant outlet (21). shaft is bent and must be replaced, along with
the main bearings.
3. Bolts (24) or studs (20).
Tighten
• Bolts (24) or studs (20) to specifications.

— 5.0L and 5.7L engines: 28 N-m (21 lbs. ft.).
— 7.4L engines: 40 N-m (30 lbs. ft.).
TORSIONAL DAMPER
1? Inspect

hub. Replace as needed.
Area of the torsional damper hub shaft which con
tacts the crankshaft front seal for roughness or
nicks. Replace the damper if this condition exists.
6A5B-38 V8 ENGINES
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.

PRIOR TO ASSEMBLY clearance 0.0127 mm (0.0005-inch) from using a full
standard bearing.
The importance of cleanliness during the assembly
procedure cannot be overstressed. Dirt will cause pre UNDERSIZE MAIN JOURNALS (5.0L AND 5.7L
mature wear of the rebuilt engine. ENGINES)
Lubricate all moving parts lightly with engine oil or • On 5.0L and 5.7L engines, when a production
engine assembly lubricant (unless specified otherwise) crankshaft cannot be precision fit by the method
during assembly. This will provide initial lubrication described previously, it is then ground 0.2286-mm
when the engine is started. (0.009-inch) undersize ON ONLY THOSE MAIN
JOURNALS THAT CANNOT BE PROPERLY FIT
CRANKSHAFT AND MAIN TED. ALL JOURNALS WILL NOT NECESSARILY
BE GROUND. A 0.2286-mm (0.009-inch) undersize
BEARING INSTALLATION bearing or 0.2540-mm (0.010-inch) undersize bear
Main bearings are the precision insert type and do ing will then be used for precision fitting in the
not use shims for adjustment. If clearances are exces same manner as previously described.
sive, a new bearing will be required. Service bearings
OVERSIZE REAR MAIN BEARING THRUST FACES
are available in standard size and 0.0254 mm (0.001
inch), 0.0508 mm (0.002 inch), 0.2540 mm (0.010 inch),
and 0.5080 mm (0.020 inch) undersize. 0.2286 mm • Some 5.0L and 5.7L production engines may have
(0.009 inch) is available for 5.0L and 5.7L engines only. rear mai n bear i ngs t hat are 0 . 2 0 3 2 mm
Selective fitting of both rod and main bearing inserts (0.008-inch) wider than standard across the thrust
is necessary to obtain close tolerances. For this reason faces.
you may use, for example, one half of a 0.0254-mm • The crankshaft on these engines can be identified
(0.001 -inch) undersize insert which will decrease the by “.008”stamped on the rear counterweight.
V8 ENGINES 6A5B-39
133 134
135
136 A. Anaerobic Sealer

130. Crankshaft
131. Rear Seal
132. Rear Main Bearing Cap F9350
Figure 70—Applying Sealant to the Block (7.4L

Engines)
3. Main bearing caps (except rear cap) and bolts to

the block.
Tighten
• Main bearing cap bolts to specifications.
— 5.0L and 5.7L engines:

130. Crankshaft • Outer bolts on #2, #3, and #4 main bear
131. Rear Seal ing caps: 95 N-m (70 lbs. ft.).
132. Rear Main Bearing Cap
•All others: 110 N-m (80 lbs. ft.).
133. Main Bearing Cap
134. Bolt — 7.4L engines: 135 N-m (100 lbs. ft.).
135. Lower Main Bearing Insert
136. U pper Main Bearing Insert
4. Rear main bearing cap and bolts to the block.
• On 7.4L engines, apply anaerobic sealing com
F9332
pound to the rear bearing cap sealing face or to
the rear bearing cap channel of the engine
Figure 69— Crankshaft and Components (7.4L block, from the corner of the rear thrust bearing
Engines) pocket to the edge of the channel as shown in
figure 70. Do not allow any sealant on either
• If the rear main bearings are replaced, they must crankshaft or rear oil seal.
have the proper distance between thrust faces to
obtain correct crankshaft end play. Tighten
a
Install or Connect (Figures 69, 70, and 71) Rear main bearing cap bolts temporarily to 4
N-m (35 lbs. in.).
NOTICE: For ste p s 4 and 5, refer to “Notice’
on page 6A5B-1. Measure (Figure 71)
1. Upper main bearing inserts to the block.
• Crankshaft end play, as follows:
Important A. Firmly thrust the crankshaft first rearward then
forward. This will line up the rear main bearing
• If any undersized bearings are used, make sure and crankshaft thrust surfaces.
they are fitted to the proper journals.
1. Crankshaft. NOTICE: Refer to “N otice” on page 6A5B-1.
2. Lower main bearing inserts to the main bearing
caps. Tighten
&
Measure
Rear main bearing cap bolts to specifications:
Main bearing clearance. Refer to SECTION 6A. — 5.0L and 5.7L engines: 110 N-m (80 lbs. ft.).
Apply engine oil to the main bearing inserts. — 7.4L engines: 135 N-m (100 lbs. ft.).
6A5B-40 V8 ENGINES
faulty insert could cause a lack of clearance at the

bearing.
— A bent crankshaft could cause binding. Make
sure the steps outlined above have been per
formed before suspecting a bent crankshaft.

INSTALLATION (7.4L ENGINES)
“►4- Install or Connect
Tool Required:
• 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
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
ously. -►4- Install or Connect (Figures 72 and 73)
L1 Inspect
Tool Required:
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).
80. SCREW, SEAL RETAINER

81. NUT, SEAL RETAINER
82. RETAINER, SEAL
83. STUD, SEAL RETAINER
84. GASKET, SEAL RETAINER
114. BLOCK, ENGINE
V2976
Figure 72—Crankshaft Rear Oil Seal Retainer (5.0L and 5.7L Engines)
V8 ENGINES 6A5B-41

Tighten
• Camshaft sprocket bolts to specifications.

Measure
Timing chain free play. The free play should not

exceed 16 mm (5/8 inch).
(5.0L and 5.7L Engines)

3. Screws (80) and nuts (81).
$ Tighten
•Screws (80) and nuts (81) to 15 N-m (11 lbs.

ft.).
4. Crankshaft rear oil seal (figure 73).
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
C. Install the seal on J 35621.
D. Position J 35621 against the crankshaft. Thread
the attaching screws into the tapped holes in
the crankshaft.
E. Tighten the screws securely with a screwdriver.
This will ensure the seal is installed squarely
over the crankshaft.
F. Turn the handle until it bottoms.
G. Remove J 35621.
CAMSHAFT, TIMING CHAIN,

AND SPROCKET INSTALLATION
■H- Install or Connect (Figures 74 and 75)
• Coat the camshaft iobes and journals with Engine

Oil Supplement (GM P/N 1052367) or equivalent.
1. Camshaft (figure 74).
• U s e three 5/16-18 bolts 100-125 mm (4-5
inches) long threaded into the camshaft’s
tapped holes to handle the camshaft.
• Use care to avoid damaging the camshaft bear
ings.
• Remove the three bolts after installation.
2. Timing chain to the camshaft sprocket.
3. Camshaft sprocket and timing chain to the engine.
Important
• Align the timing marks on the camshaft sprock

et and crankshaft sprocket (figure 75).
Camshaft sprocket bolts. Use the bolts to draw the
camshaft sprocket onto the camshaft. DO NOT
A TTEMPT TO HAMMER THE CA MS H A F T
SPROCKET ONTO THE CAMSHAFT. DOING SO
MAY DISLODGE THE REAR CAMSHAFT PLUG.
6A5B-42 V8 ENGINES
FRONT COVER INSTALLATION TORSIONAL DAMPER

INSTALLATION
|-n-| Install or Connect (Figure 76)
*►4- Install or Connect (Figure 77)
• Lubricate the lips of the crankshaft front oil seal
with engine oil. Tools Required:
J 39046 Torsional Damper Puller and Installer
1. Gasket (90).
2. Front cover (91). 1. Crankshaft key.
NOTICE: The inertial w eig h t se c tio n o f the

NOTICE: Refer to “N otice” on page 6A5B-1. torsional dam per is a ssem b led to the hub
with a ru b b er ty p e m aterial. The co rrect
installation procedures (with the proper tool)
3. Bolts (93).
m u st be followed or m ovem ent o f the inertial
w eig h t s e c tio n o f th e h u b will d e s tr o y th e
$ Tighten tuning o f the torsional damper.
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.
5. Torsional damper bolt and washer.
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
Figure 76—Front Cover
ROD INSTALLATION
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.
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:
• 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.
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
• Each connecting rod and bearing cap

should be marked, beginning at the front of
the engine. Cylinder 1, 3, 5 and 7 are the
right bank and 2, 4, 6, and 8 are the left
bank (when viewed from the front of the Figure 79—Piston Ring End Gap Location (7.4L
engine). The numbers on the connecting rod Engines)
when installed in the cylinder bore. If a con
necting rod is ever transposed from one
block or cylinder to another, new connecting
rod bearings should be fitted and the con
necting rod should be numbered to corre
spond with the new cylinder number.

3. Connecting rod cap with bearing insert and nut.
Measure

SECTION 6A. Then apply engine oil to the con
necting rod bearing.
£ Tighten
Connecting rod bolt nuts to specifications.

6A5B-44 V8 ENGINES
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:
— 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).
Tighten
• 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
70. Oil Pump

76. Nut
77. Bolt
79. Oil Pan Baffle
F9365
Figure 84—Oil Pan Deflector (5.0L and 5.7L

Engines)
7.4L ENGINES A. Sealing Compound

74. Gasket
Install or Connect (Figure 85) 75. Bolt
76. Oil Pan
•Apply RTV sealer (GM P/N 12346141) or equiva
F9331
lent in four places where the front and rear main
bearing caps meet the engine block as shown in Figure 85—Oil Pan (7.4L Engines)
figure 85.
1. Gasket (74) to the block. 2. Cylinder head. Carefully guide the cylinder head
2. Oil pan (76). Make sure the gasket stays in place. into place over the dowel pins and head gaskets.
3. Cylinder head bolts. Coat the threads of the bolts
with sealing compound (Loctite #592 or equivalent)
3. Bolts (75). and install finger tight.
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
Figure 86—Cylinder Head (5.0L and 5.7L Engines)
VALVE TRAIN COMPONENT • Lubricate the feet of the lifters with “Moly Kote.”
INSTALLATION 1. Hydraulic lifters (44 or 209) to the block.

2. Pushrods (43 or 210). Seat the pushrods into the
Important socket in the hydraulic lifters.
• The 7.4L engine uses different length intake
Replace all hydraulic lifters if a new camshaft is
and exhaust pushrods. The exhaust valve push
installed.
rods are longer than the intake valve pushrods.
Install or Connect (Figures 88 and 89) • Coat the mating surfaces of the rocker arms (42)
and balls (41) with “Moly Kote” or equivalent.
Lubricate the hydraulic lifter bodies with Engine Oil
Supplement (GM P/N 1052367) or equivalent. 3. Pushrod guides (260), 7.4L engines only.
4. Rocker arms (42).
5. Balls (41).
6. Nuts (40), on 5.0L and 5.7L engines or bolts (40)

on 7.4L engines.
Q , Tighten
• Bolts (40) to 54 N-m (40 lbs. ft.), 7.4L engines

only.
Adjust
• Valves (5.0L and 5.7L engines only).

• No valve adjustment is required for 7.4L
engines after tightening the rocker arm bolts to
54 N-m (40 lbs. ft.).
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
40. NUT, ROCKER ARM

41. BALL, ROCKER ARM
42. ARM, ROCKER
46. HEAD, CYLINDER
144. BLOCK, ENGINE
209. LIFTER, VALVE
210. PUSHROD
V2881
Figure 88—Valve Train Components (5.0L and 5.7L Engines)
40. Bolt
41. Ball
42. R ocker Arm
43. Pushrod
44. Hydraulic Lifter
46. C ylinder Head
260. Pushrod Guide
F9325
Figure 89—Valve Train Components (7.4L Engines)

6A5B-48 V8 ENGINES
INTAKE MANIFOLD
INSTALLATION
0.. 0 ... ®'—......®— 0-

5.0L AND 5.7L ENGINES
+4- Install or Connect (Figures 94 and 95)
1. Gaskets (22) to the cylinder heads.

0 ( $ ) ® ® © ® 0 © . • Make sure the tab and/or arrow faces the front
of the engine. The side stamped “This Side
Down” must face the cylinder head.
2. RTV sealant to the front and rear intake manifold
B9572
sealing surfaces on the block as follows:
Figure 90—Cylinder Head Bolt Tightening • Refer to figure 94.
Sequence (5.0L and 5.7L Engines) • Apply a 5 mm (3/16-inch) bead of RTV sealer
(GM P/N 1052289 or equivalent) on the front
and rear of the block. Extend the bead 13 mm
(1/2 inch) up each cylinder head to seal and
retain the gaskets.
3. Intake manifold (21) to the engine.
4. Intake manifold bolts (19) and studs (20).
Tighten
Bolts (19) and studs (20) to 47 N-m (35 lbs. ft.)

using the tightening sequence shown in figure
95.
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
3. Intake manifold (21).
4. Bolts (20).
Tighten
• Bolts (20) to 40 N-m (30 lbs. ft.). Use the tight

ening sequence shown in figure 97.
ROCKER ARM COVER

INSTALLATION
+«- Install or Connect (Figures 98 and 99)
1. Gaskets (34).
2. Rocker arm covers (32).
Engines) NOTICE: Refer to “N otice” on page 6A5B-1.
3. Bolts.
Figure 94—Intake Manifold (5.0L and 5.7L Engines)

6A5B-50 V8 ENGINES
3. Washers (2), tab washers (3), (5.0L and 5.7L

engines), and bolts/studs (4).
Tighten
O • Bolts/studs to specifications:
O — 5.0L and 5.7L engines:
O Of • Two center bolts: 36 N-m (26 lbs. ft.).

• Outside bolts: 28 N-m (20 lbs. ft.).
i
• Bend the tab washers against the bolt
< ■ ■ ■ FRONT ■ ■ ■ ■ heads.
B9569
Figure 95—Intake Manifold Bolt Tightening
Sequence (5.0L and 5.7L Engines) COOLANT PUMP INSTALLATION
Tighten
• Bolts to specification:
— 5.0L and 5.7L engines: 10 N-m (89 lbs. in.). 1. Gaskets (11).
— 7.4L engines: 8 N-m (70 lbs. in.). 2. Coolant pump (10).
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).
^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
Figure 96—Intake Manifold (7.4L Engines)

V8 ENGINES 6A5B-51
3706S1893
Figure 97—Intake Manifold Tightening Sequence

(7.4L Engines)
FLYWHEEL INSTALLATION
-n - Install or Connect (Figure 36 and 37)
1. Flywheel (110A or 11 OB).
NOTICE: Refer to “N otice” on page 6A2B-1. 32. Rocker Arm Cover

34. Gasket
36. Bolt
2. Flywheel bolts (111).
F9362
Figure 98—Rocker Arm Cover Installation (5.0L and

5.7L Engines)
30 B O LT
32 R O C K ER ARM COVER
3706S3013
Figure 99—Rocker Arm Cover Installation (7.4L Engines)

6A5B-52 V8 ENGINES
Figure 100— Exhaust Manifold (5.0L and 5.7L Engines)
1 EXH AUST M AN IFO LD

4 B O L T /S T U D
6 S P A R K P L U G HEAT S H IE LD
3706S3005
Figure 101—Exhaust Manifold (7.4L Engines)
$ Tighten ENGINE ACCESSORY

•Bolts (111) to 100 N-m (74 lbs. ft.) (5.0L/5.7L
INSTALLATION
Engines). Install the engine accessories (TBI unit, distributor, oil
filter, generator, etc.) as directed in the proper on-vehi-
•Bol t s (111) to 90 N-m (66 lbs. ft.) (7.4L
cle Truck Service Manual. Connect all vacuum hoses
Engines).
and electrical equipment the same way as removed.
V8 ENGINES 6A5B-53
10. Coolant Pump 12. Bolt

11. Gasket 13. Plug F9349
Figure 103— Coolant Pump (7.4L Engines)
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
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.
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.
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
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 )
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
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
Production
PISTON:
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
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
*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
Journal Taper
#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
Diameter 2.0988-2.0998
Taper
Crankpin Service Limit 0.001 {Maximum)
Clearance Service Limit 0.003 (Maximum)
CAMSHAFT:
Lobe Intake 0.2336 0.2565
Lift ±0.002 Exhaust 0.2565 0.2690
VALVE SYSTEM:
Lifter Hydraulic
Intake
Valve Lash One Turn Down From Zero Lash
Exhaust
Intake 1/32-1/16
Seat Width
Exhaust 1/16-3/32
Intake 0.0010-0.0027
Production
Service
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
Damper Approx. # of Coils 4
T2369
6A5B-56 V8 ENGINES
SPECIFICATIONS
GENERAL DATA:
Type V8
Displacement 7.4L (454 CID)
RPO L19
Bore 4.25
Stroke 4.00
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
Production
PISTON:
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
0 Clearance Service Limit Hi Limit Production + 0.001
i
Gap
Service Limit Hi Limit Production + 0.010
PISTON PIN:
Diameter 0.98945-0.98965
‘ 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
Main Taper
Journal
#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
Diameter 2.1990-2.1996
Production 0.0005
Taper
Crankpin Service Limit 0.001
Round Service Limit 0.001
Clearance Service Limit 0.003 (Maximum)
CAMSHAFT:
Lobe Intake 0.2487
VALVE SYSTEM:
Lifter Hydraulic
Intake
Valve Lash Net Lash
Exhaust
Intake 1/32-1/16
oeai vviuin
Exhaust 1/16-3/32
Intake 0.0010-0.0027
Production
Service
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.)
Item N-m Lbs. Ft. Lbs. In
Camshaft Sprocket Bolts...................................................................................... 28 21 —
Connecting Rod Bolt Nuts.................................................................................... 61 45 —
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 —
Engine Block Drain Plug....................................................................................... 22 16 —
Center Two Bolts................................................................................................ 36 26 —
All Other Bolts.................................................................................................... 28 20 —
Flywheel Bolts........................................................................................................ 100 74 —
Flywheel Housing Bolts......................................................................................... 44 32 —
Front Cover Bolts................................................................................................... 11 — 97
Intake Manifold Bolts (In Sequence)................................................................... 47 35 —
Main Bearing Cap Bolts
Outer Bolts on #2, #3, and #4 Caps.............................................................. 95 70 —
All Others............................................................................................................. 110 80 —
Oil Filter Bypass Valve Bolts................................................................................ 26 20 —
Oil Pan Baffle Nuts (H.D. 5.7L Only).................................................................. 36 27 —
Oil Pan Bolts........................................................................................................... 11 — 97
Oil Pan Drain Plug................................................................................................. 22 16 —
Oil Pan Nuts............................................................................................................ 22 16 —
Oil Pan Studs to Oil Seal Retainer or Engine Block....................................... 2 — 15
Oil Pump Bolt......................................................................................................... 90 65 —
Oil Pump Cover Bolts........................................................................................... 12 — 106
Rocker Arm Cover Bolts....................................................................................... 10 — 89
Torsional Damper Bolt........................................................................................... 95 70 —
(7.4L ENGINES)
Item Nm Lbs. Ft. Lbs. In
Camshaft Sprocket Bolts...................................................................................... 26 20 —
Connecting Rod Bolt Nuts.................................................................................... 61 45 —
Coolant Outlet Bolts............................................................................................... 40 30 —
Coolant Pump Bolts............................................................................................... 40 30 —
Cylinder Head Bolts (In Sequence)..................................................................... 115 85 —

Engine Block Drain Plug....................................................................................... 12 — 112
Exhaust Manifold Bolts......................................................................................... 54 40 —
Flywheel Bolts........................................................................................................ 90 66 —
Flywheel Housing Bolts......................................................................................... 40 30 —
Front Cover Bolts............................. ..................................................................... 12 — 106
Intake Manifold Bolts (In Sequence)................................................................... 40 30 —
Main Bearing Cap Bolts........................................................................................ 135 100 —
Oil Pan Bolts........................................................................................................... 22 16 —
Oil Pan Drain Plug................................................................................................. 28 20 —
Oil Pump Bolt.......................................................................................................... 90 65 —
Oil Pump Cover Bolts............................................................................................ 12 — 106

Rocker Arm Bolts................................................................................................... 54 40 —
Rocker Arm Cover Bolts....................................................................................... 8 — 70

Torsional Damper Bolt........................................................................................... 149 110 —
T2525
V8 ENGINES 6A5B-59
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
16. CRANKSHAFT SPROCKET INSTALLER
17. CRANKSHAFT REAR OIL SEAL INSTALLER
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.).
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
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.
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.
Figure 1—Flywheel removal Figure 2—Oil Pump Drive Removal

6.5L DIESEL 6A7-5
Figure 3—Intake Manifold Left Side Figure 5—Injection Lines
3. Fuel return line brackets on front left and right side

of rocker covers.
4. Fuel return hose from the injection pump.
5. Fuel return lines as an assembly.
INJECTION NOZZLE REMOVAL

+-► Remove or Disconnect
Tool Required:
J 29873 Nozzle Socket
NOTICE: When rem oving an injection nozzle,

u se J 29873. R em ove the nozzle using the
30-mm h e x portion. Failure to do s o will
result in damage to the injection nozzle.
1. Injection nozzle using J 29873. Store the nozzles

in a clean place.
2. Gaskets.
1. Injection line clips at the brackets.

2. Heat shield on right side.
3. Injection lines at the nozzles, using a 22 mm open
end wrench to hold nozzle body while loosening
injection line.
• Cap the lines and nozzles immediately.
• Do not bend injection lines.
4. Injection lines at the pump.
• Cap the lines and pump fittings immediately.
• Tag the lines for installation.
5. Injection line brackets.
RETURN LINE REMOVAL

1. Clamps.
2. Fuel return hoses at injector nozzles. Figure 6—Return Lines
6A7-6 6.5L DIESEL
GLOW PLUG REMOVAL

• Glow plugs. Use a 3/8-inch, deep socket.
EXHAUST MANIFOLD REMOVAL

Remove or Disconnect (Figures 8, 9, and 10)
1. Exhaust manifold bolts.

2. Exhaust manifolds.
DIPSTICK TUBE REMOVAL

1. Dipstick bracket nut.

2. Dipstick tube. Pull out to remove.
3. O-ring seal from the dipstick tube.
Figure 9—Exhaust Manifold Right Side (L49,L57)
Figure 7—Glow Plug Removal

Figure 10—Exhaust Manifold Right Side (L56,L65)
OIL FILLER NECK REMOVAL

+ •¥ Remove or Disconnect (Figure 11)
1. Nut holding bracket to thermostat housing.

2. Nuts from filler neck bracket to front of engine
3. Oil filler neck.
4. Seal
THERMOSTAT
HOUSING/THERMOSTAT
REMOVAL
1. Nut holding fuel filter water drain valve.

2. Bolts to thermostat housing.
3. Thermostat housing.
4. Gasket.
5. Thermostat.
6.5L DIESEL 6A7-7
Figure 11—Filler Neck Removal Figure 13—Thermostat Housing/Thermostat

(G and P Models)
COOLANT CROSSOVER
REMOVAL
«■+ Remove or Disconnect (Figures 14 and 15)
1. Engine coolant temp. sensor.(L49,L56 and L65

only)
2. Clamps from by-pass hose.
3. Bolts or studs from crossover.
4. Coolant crossover.
5. By-pass hose.
6. Gaskets.
Figure 14— Coolant Crossover (C/K Models)
ROCKER ARM COVER

REMOVAL
1. Rocker arm cover bolts.
NOTICE: Do not pry on the rocker arm cover.

Damage to sealing surfaces m ay result. Use
a block o f wood against the side o f rocker
cover and strike with a ham m er in a side
ways direction to shear RTV sealant.
2. Rocker arm covers.

Figure 12—Thermostat Housing/Thermostat
(C/K Models)
6A7-8 6.5L DIESEL
Figure 15—Coolant Crossover (G and P Models) Figure 17—Rocker Arm Assembly
each end. A paint stripe identifies the upper end

of the pushrod. If the paint stripe is not visible,
mark the pushrods on the upper end as they
are removed.
• Mark the pushrods so they can be installed in
the same location at assembly.
CYLINDER HEAD REMOVAL

++ Remove or Disconnect (Figure 18)
1. Fuel injection pump fast idle cold advance switch.

(L57 only, located at rear of right cylinder head)
2. Cylinder head bolts.
3. Cylinder heads.
4. Head gaskets.
Figure 16—Rocker Arm Cover
ROCKER ARM AND

PUSHROD REMOVAL
1. Bolts from rocker shafts.

2. Rocker arm assemblies.
Important
• Mark the rocker arm assemblies so they can be

returned to the original location at assembly.
3. Pushrods.
Important
The pushrods must be installed in the original

direction at assembly. This is because the
pushrods have a different degree of hardness at Figure 18—Cylinder Head Removal
6.5L DIESEL 6A7-9
HYDRAULIC LIFTER REMOVAL
1. Bolts and clamps.

2. Guide plates.
3. Hydraulic lifters.
Important
• Place the lifters in an organizer rack. The lifters

must be installed in the same bore from which
they were removed.
*■+ Remove or Disconnect (Figure 20 and 21)

Figure 20—Coolant Pump and Plate
1. Bolts and studs holding the coolant pump and cool

ant pump plate to the front crankcase cover.
2. Coolant pump with coolant pump plate.
3. Bolts holding the coolant pump to the coolant pump
plate.
4. Coolant pump.
5. Gasket.
TORSIONAL DAMPER REMOVAL

Tool Required:
J 39046 Torsional Damper Remover
J 23523-2 Screw
1. Bolt and washer.

2. Torsional damper. Use J 39046 with J 23523-2.
Figure 19— Hydraulic Lifter Removal

6A7-10 6.5L DIESEL
INJECTION PUMP REMOVAL

1. Wires and hoses at the injection pump as required.

2. Three bolts from injection pump timing gear.
3. Injection pump timing gear.
4. Three nuts and Throttle spring bracket if equipped.
(L57 only)
5. Injection pump.
6. Gasket.
FRONT COVER REMOVAL

1. Crankshaft sensor from front cover. (L49, L56, L65

only)
2. Oil pan to front cover bolts.
3. Front cover to block bolts.
4. Front cover.
TIM ING CHAIN AND

SPROCKET REMOVAL
Measure
• Timing chain free play as follows:

1. Mount a dial indicator to the front of the block.
2. Position the dial indicator so that the plunger con
tacts the timing chain between the two gears.
3. Pull the chain outward (parallel to the front face of
the block) the maximum amount with finger pres
sure on the inside of the chain.
4. Set the dial indicator to zero.
5. Move the chain inward (parallel to the front face of
the block) the maximum amount with finger pres
sure on the outside of the chain.
The total indicator travel can be noted. With used
parts, the deflection must not exceed 20.3 mm
Figure 23—Injection Pump Timing Gears (0.80 inch). If the deflection exceeds this limit, the
sprockets and timing chain must be replaced as an
assembly.
1. Bolt and washer from camshaft gear.

2. Camshaft gear.
3. Camshaft sprocket with timing chain.
4. Crankshaft sprocket.
CAMSHAFT REMOVAL
1. Bolts, thrust plate and spacer.

2. Camshaft.
A. The mechanical fuel pump (lift pump) and push
rod (L57, L49 Full size van) must be removed
prior to removing the camshaft.
B. Pull the camshaft from the block carefully to
Figure 24—-Electronic Injection Pump avoid damage to the camshaft bearings.
6.5L DIESEL 6A7-11
Figure 26—Timing Chain, Sprocket and Camshaft Figure 28—Oil Pump
OIL PAN REMOVAL
|+-»| Remove or Disconnect (Figure 27)
1. Bolts.
2. Oil pan.
3. Oil pan rear seal.
OIL PUMP REMOVAL

1. Bolt.
2. Oil pump and extension shaft.
Figure 29—Removing The Piston and Connecting

Rod

ROD REMOVAL
4“+ Remove or Disconnect (Figure 29)
1. Ridge or deposits from the upper end of the cylin

der bores.
A. Turn the crankshaft until the piston is at BDC.
B. Place a cloth on top of the piston.
C. Perform the cutting operation with a ridge ream
er (figure 30). Do not remove excessive mate
rial. Excessive removal of material may
require cylinder reboring to the next over
size.
D. Turn the crankshaft until the piston is at TDC.
E. Remove the cloth and cuttings.
2. Mark the cylinder number on the top of each pis
ton.
6A7-12 6.5L DIESEL
REAR CRANKSHAFT SEAL

REMOVAL
fS j Remove or Disconnect (Figure 31)
1. Oil seal using a small screw driver. Do not reuse

old seal.
CRANKSHAFT REMOVAL
A. Cloth
F9385
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.
Figure 31—Rear Crankshaft Seal Figure 32—Crankshaft and Components

6.5L DIESEL 6A7-13

You will need a solvent tank large enough to hold the Clean
larger engine parts, along with various bristle brushes
and a gasket scraper. A source of compressed air will 1. Block in solvent.
be helpful in the cleaning operations. 2. Block gasket surfaces.
Precision measuring tools will be required for the 3. Cylinder bores.
inspection procedure. These include: micrometers, cyl 4. Oil galleries and passages.
inder bore gage, feeler gages, dial indicator set, etc. 5. Scale deposits from the coolant passages.
The inspection work, performed with the proper method
and tools, is most important. The rebuilt engine cannot I? Inspect
be expected to perform properly if parts worn beyond
acceptable limits are reused. 1. Hydraulic lifter bores for deep scratches and var
nish deposits.
BLOCK 2. Block for cracks.
• Cylinder walls.
The 6.5L uses a pipe plug to block the turbocharger • Coolant jackets.
oil supply. On manual transmission applications a valley • Main bearing webs.
drain tube is used at the rear of the block. This drain • Engine mount bosses.
tube prevents fuel or oil that has collected in the valley 3. Main bearing bores and main bearing caps.
from draining onto the clutch and flywheel. Engines • All main bearing bores should be round and
equipped with automatic transmissions do not use a uniform in ID at all bearing supports.
drain tube. • The area where the main bearing inserts con
tact the main bearing bore must be free of burrs
OIL FILTER BYPASS VALVE AND BLOCK PLUG
and scratches.
4. Head gasket surface for scratches, burrs and dam
Remove or Disconnect (Figure 33) age.
1. Block drain (if used). Measure

2. Expansion plugs and block heater.
3. Oil galley plugs. Fire deck warpage. Use a straight edge and feeler
4. Oil filter bypass valve. Using a screwdriver. gage. If the block is warped more than 0.15 mm
5. Oil cooler bypass valve. (0.006 inch) longitudinally or 0.08 mm (0.003 inch)
transversely, it should be replaced.
A. Center punch the cup plug leaving 3.2 mm (1/8
inch) hole. NOTICE: Do not attem pt to resurface the fire
B. Install a 4.8 mm (3/16 inch) sheet metal screw d eck or cylinder head.
into hole in cup plug.
C. Using two heel bars, take out cup plug. Install or Connect (Figure 33)
D. Using a slide hammer remove oil cooler bypass
valve. 1. Oil cooler bypass valve, using a socket to drive the
bypass valve into the bore until seated on the
shoulder in the bore.
2. Cup plug for oil cooler bypass valve. (This plug has
an orifice hole that prevents an air lock from occur
ring and blocking oil flow).
3. Oil filter bypass valve.
• Use a socket to drive valve into bore until it
seats against shoulder in bore.
4. Expansion plugs and oil galley plugs.
5. Block heater.
6. Block drain bolt (if used).
• Bolt to 25 N-m (18 lbs. ft.).
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
Measure PISTON AND CONNECTING

Cylinder bores for out of round and taper. Refer to
ROD ASSEMBLIES
SECTION 6A. DISASSEMBLY
CYLINDER BORE RECONDITIONING GUIDELINES Disassemble
*
Refer to SECTION 6A. Additional guidelines are listed
below: Refer to “PISTON AND CONNECTING ROD ASSEM
BLIES” in SECTION 6A.
• Fine vertical scratches will not by themselves
cause excessive oil consumption. Therefore honing 9 Important
to remove them is unnecessary.
• There is only one production standard piston grade • Production standard 6.5L pistons are available
size. When production standard grade size pistons in one grade size, identified by a “J” (naturally
are used in all eight cylinder bores, a “J” is metal aspirated) or “JT” (turbocharged) ink or metal
stamped in a single place on the cylinder block oil stamped on the top or bottom of the piston.
pan rail. There is also a production oversize piston
• A 0.13 mm oversize production piston is available grade size available for in-plant rework, which is
for in-plant rework of cylinders that do not meet the identified by an “S” (naturally aspirated) or “ST”
production standard specification. These production (turbocharged) ink or metal stamped on the top
oversize cylinder bores are identified by an “S” or bottom of the piston. To insure that each
metal stamped on the pan rail next to any piston is installed in its original bore during
reworked cylinder. A “J” will also be metal stamped reassembly, mark the piston according to its
in a single place on the oil pan rail to represent bore during removal. This step is necessary if
that all remaining cylinders are production stan the piston is removed from the connecting rod.
dard. 1. Piston pin retainer. Pry out with a small
• If a significant area of the bore is polished through screwdriver or scribe with a rounded end.
the hone marks, but otherwise serviceable, break 2. Piston pin.
the polished surface lightly with a finish hone and
• Slide the pin from the piston.
install new rings. Refer to “Finish Honing.”
• All service oversize pistons are of the same weight 3. Piston from the connecting rod.
as the production pistons, therefore engine balance
is not affected by using service oversized pistons.
• If honing is not required, prepare the cylinder bores Refer to SECTION 6A for information regarding the
for reuse by cleaning with a hot water and deter following:
gent wash. Apply clean engine oil to the bore after • cleaning
cleaning. • inspecting
BORING PISTON MEASUREMENT

The piston skirts are barrel-shaped so the piston
SECTION 6A contains general information on the diameter must be measured at a specific gage point
subject of boring and honing. A detailed description of (figure 34).
types of equipment, speeds, feeds, grid sizes of honing
stones, cycle times, etc. is beyond the scope of this
manual.
• When taking the final cut with a boring bar, leave
approximately 0.13 mm (0.0050 inches) on the
diameter for rough and finishing honing.
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
• The piston gage point is 65.33 mm from the top

of the piston.
PISTON SELECTION
To determine the piston to cylinder bore clearance
perform
the following measurements:
Measure
Cylinder bore. Refer to “Cylinder Bores” in this

section. If the bore is serviceable, note the lowest
bore diameter measurement. Then compare this
measurement to the piston measurement.
Figure 37—Measuring Piston Pin Bushing Inside

Diameter
• Piston as outlined under “Piston Measurement” in

this section. Compare the piston measurements to
the piston-to-cylinder-bore specifications found at
the rear of this section. Subtract the piston
diametter from the lowest bore diameter to deter
mine piston-to-bore clearance.
If the used piston is not acceptable, determine if a
new piston will fit the cylinder bore by using the above
measurement procedures.
MEASURING PISTON PIN TO PISTON PIN BUSHING

CLEARANCE
Clean
• Piston pin and bushing. The parts must be free of

oil and dirt.
Measure (Figures 35, 36 and 37)

Figure 35— Measuring Piston Pin Diameter
1. Piston pin diameter (figure 35). Check against
“Specifications.”
2. Piston Pin Hole Diameter. Use an inside microme
ter (figure 36).
3. Piston pin bushing ID. Use an inside micrometer
(figures 37).
4. Piston pin to bushing clearance. Subtract the pis
ton pin diameter from the piston pin bushing ID.
Compare with specifications at the rear of this sec
tion. If the clearance is excessive, try a new piston
pin. If the clearance is excessive with a new piston
pin, the connecting rod must be replaced. Replace
ment bushings are not available.
ASSEMBLING THE PISTON AND CONNECTING

ROD
Tool Required:
J 39507 Piston Retaining Ring Installer
1. Piston to the connecting rod.
6A7-16 6.5L DIESEL
Measure
• Ring end gap as follows:

1. Select rings that will be used in the bore being
checked.
2. Slip the compression ring into the cylinder bore,
then press it down about 25 mm (1-inch) above
ring travel. Make sure the ring is square with
the cylinder wall.
3. Measure the space or gap between the ends of
the ring with a feeler gage.
4. Refer to “Specifications” in the proper section.
5. This gap measurement applies to a new ring
used in a new bore for the service standard
piston. If a new ring is being used in a worn
bore, the end gap may be slightly more than
specifications.
* Assemble
• Piston rings. Refer to the instructions furnished with

the parts package.
• While assembling rings onto piston rotate rings to
check for binding. If binding occurs inspect ring
grooves for dirt or damage, such as nicks caused
by improper installation.
Measure
Ring clearance. Use a feeler gage. Compare with

specifications at the rear of this section.
INTAKE AND EXHAUST

MANIFOLDS
| Clean
Old pieces of gasket from the gasket surfaces.

Figure 39—Assembly View Soot deposits from the intake manifold.
•T h e piston must be installed with the piston

crown indent on the same side as the connect
L* Inspect
ing rod bearing tang slots.

Manifolds for cracks, broken flanges, and gasket
2. Piston pin.
surface damage.
• Apply engine oil to the pin and push into place.
3. Retaining rings. Use J 39507 (figures 38 and 39).
CAMSHAFT
Inspect
Important
• Retaining rings for proper assembly. Visually
inspect retaining ring to ensure it is seated in
• Whenever the camshaft needs to be replaced, a
the ring groove.
new set of
INSTALLING THE PISTON RINGS hydraulic lifters must also be installed.
• All compression rings are marked on the upper
side of the ring. When installing the compression
rings, make sure the MARKED SIDE IS TOWARD L* Inspect
THE TOP OF THE PISTON.
• The top compression ring is a keystone type. Camshaft lobes and journals for scratches, pitting,
• The oil ring is a two-piece type, consisting of an scoring, and wear.
expander and a scraper ring. Thrust plate for wear and scoring.
6.5L DIESEL 6A7-17
* Assemble (Figures 41)
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
• The bearing oil hole MUST align with the oil

Figure 40—Measuring the Camshaft Journals hole in the block located at the 1 o’clock posi
tion. The bearing seam must be located in the
|j| Measure (Figure 40) 11 o’clock position.
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
• The bearing oil hole on inner camshaft bearings

MUST align with the oil hole in the block located NOTICE: If the timing chain, timing gears,
at the 1 o’clock position. The bearing seam fro n t co ver, c r a n k s h a ft p o sitio n s e n s o r ,
must be located in the upper half of the block at crankshaft or other com ponent(s) affecting
approximately 11 o’ clock. timing are replaced, it will be necessary to
4. New rear camshaft plug. reprogram TDC O ffset into the PCM. Refer to
the appropriate Driveability, Em issions and
A. Coat the camshaft plug with sealer (Loctite 592 Electrical Diagnosis Manual. (L49 VIN P, L56
or equivalent). VIN S, L65 VIN F only)
B. Install the plug flush to 0.80-mm (1/32-inch)
deep.
COOLANT PUMP
TIM ING CHAIN, SPROCKETS
AND TIM ING GEARS
Inspect The coolant pumps used with the serpentine belt sys
lv tem all rotate counterclockwise (CCW). The pump bod
A. Sprockets for chipped teeth and wear. ies are the same except for the bypass hose fitting. The
B. Timing chain for damage. P and G van chassis coolant pump use a 5/8-inch O.D.
bypass fitting. CK models use a 1-inch O.D. fitting. The
• It should be noted that excessively worn 1-inch fitting is used with a blocking bypass thermostat.
sprockets will rapidly wear a new chain. Like
wise, an excessively worn chain will rapidly Py| Clean
wear a new set of sprockets.
• Old gasket from the gasket surfaces on the coolant
C. Timing gears on the injection pump and camshaft
pump and coolant pump plate.
for wear and broken teeth.
Important
NOTICE: If the timing chain, timing gears,
fro n t co ver, c r a n k sh a ft p o s itio n se n so r, Do not immerse the pump in solvent. The sol
crankshaft or other com ponent(s) affecting vent may enter the pump’s permanently lubri
timing are replaced, it will be n ecessa ry to cated bearings, dissolve the bearings’ lubricant
reprogram TDC O ffset into the PCM. Refer to supply, and cause premature bearing failure.
Electrical Diagnosis Manual. (L49 VIN P, L56 I? Inspect
VIN S, L65 VIN F only)
* Coolant pump shaft for roughness and end play. If
FRONT COVER the shaft does not turn smoothly, or if there is
excessive end play, replace the coolant pump.
Clean ►Coolant pump body at the drain hole. If there is
evidence of coolant leakage, the coolant pump
shaft seal is leaking and the coolant pump should
• Old sealer from the sealing surfaces.
be replaced.
Inspect »Coolant pump plate for damage.
lv
Baffle for damage. OIL PAN AND ROCKER ARM

Front cover for cracks and damage to the sealing COVERS
surfaces.
j| Clean
I* Disassemble
• Parts in solvent. Remove all sludge and varnish.
Front crankshaft seal. Pry the seal out with a large »Old sealer from the sealing surfaces.
screwdriver.
Inspect
* Assemble
• Sealing flanges for bending or damage.
Tool Required:
• Rubber grommets and parts on the rocker arm cov
A. Front crankshaft seal. Use J 22102. The open end • Oil pan for rock damage or cracks.
of the seal must face inside the cover. • Oil pan baffle for loose fit.
B. Coat the seal lips with grease. • Drain plug threads for stripping.
6.5L DIESEL 6A7-19
OIL PUMP Clean
A. Parts in solvent. Blow dry with compressed air.

❖ Disassemble
Wear protective safety glasses and gloves.
1. Oil pump cover screws. B. Make sure the oil passages in the pushrods are
2. Oil pump cover. clear.
• Mark the gear teeth so the pump gears can be ❖ Disassemble

installed with the same gear teeth indexed.
1. Rocker arm retainers .
3. Drive gear and shaft.
4. Idler gear. A. Insert a screwdriver into the rocker arm shaft
5. Pressure regulator valve retaining pin, valve, bore and break off the end of the retainers.
spring, and related parts. B. Pull the rocker arm retainers out with pliers.
2. Rocker arms from the rocker arm shaft. Mark the
• Note the order of assembly. rocker arms so they can be returned to their origi
nal locations at assembly.
Clean
1? Inspect
All parts in clean solvent and blow dry with com
pressed air. Wear protective safety glasses and Rocker arms and shafts at their mating surfaces.
gloves. These surfaces should be smooth and free from
scoring or other damage.
L* Inspect Rocker arm areas which contact the valve stems
and the sockets which contact the pushrods. These
Pump body and cover for cracks or other damage. areas should be smooth and free of damage and
Gears for wear. wear.
Drive gear and shaft for improper fit in the pump Pushrods for bending. Roll the pushrod on a flat
body. surface to determine if it is bent. Replace if neces
Inside of the cover for wear that would permit oil to sary.
leak past the ends of the gears. The pump gears, Ends of the pushrods for scoring or roughness.
cover, and body are not serviced separately. If the Hydraulic lifter guide plates and clamps for dam
parts are damaged or worn, replace the entire oil age.
pump assembly.
Pickup screen and pipe for damage to the screen, * Assemble
pipe or relief grommet.
1. Rocker arms to the rocker arm shaft. Used rocker
* Assemble arms must be returned to their original locations.
1. Pressure regulator valve and related parts. Important

2. Idler gear and drive gear with shaft. Align the
marks made during disassembly. • Lubricate the rocker arms with engine oil before
installing.
• Prime oil pump by filling cavity with assembly 2. New rocker arm retainers.
lubricant.
A. Center the rocker arms on the corresponding
3. Oil pump cover. holes in the rocker arm shaft.
4. Oil pump cover screws. B. Install the retainers with a drift of at least
13-mm (1/2-inch) diameter.
$ Tighten
HYDRAULIC LIFTERS
Screws to 16 N-m (12 lbs. ft.). Refer to SECTION 6A.
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
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:
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
Valve Guides and Valve Seats Measure (Figures 44 and 45)
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
E. Repeat the preceding steps on the remaining
valves. Figure 44— Cutaway Scale
6A7-22 6.5L DIESEL
replaced. The nozzle holder will then be checked and

repaired at a centralized location.
When performing the injection nozzle tests, refer to
the instructions provided with the nozzle tester
J 29075-B.
•Test Lines - 6x2x400-mm (1.5-mm bore).
•Test Fluid - per ISO 4113 (Example: Shell V 1399,
Viscosity 1487C or equivalent).
• Kinetic Viscosity at 4°C (40°F) - per ISO 3104: 2.45
to 2.75mm/second.
• Test oil temperature during test: 20 to 25° C (68° to
77° F).
1. Connect the nozzle holder assembly to the test
line.
2. Place clear plastic tubes on overflow connections
to prevent leakoff from being confused with actual
leak.
3. Close the shutoff valve to the pressure gage.
Figure 45—Measuring Valve Spring Installed Height
CAUTION: When testing nozzles, do not place
your hands or arms near the tip of the nozzle.
Jp Inspect
The high pressure atomized fuel spray from a
nozzle has sufficient penetrating power to
• Coolant outlet and coolant crossover for cracks.
puncture flesh and destroy tissue and may
Thermostat Check result in blood poisoning. The nozzle tip
1. Suspend the thermostat and a thermometer in should always be enclosed in a receptacle,
water with the thermometer located close to the preferably transparent, to contain the spray.
thermostat. The thermostat must be completely
submerged and the coolant thoroughly agitated 4. Fill and flush the nozzle holder assembly with test
while heating. Apply heat to the coolant and record oil by activating the lever briskly and repeatedly.
both the temperature at which the thermostat This will apply test oil to all functionally important
begins to open and the temperature at which the areas of the nozzle and purge it of air.
thermostat is fully open. The thermostat should
begin to open at 1.6°C (4°F) above or below the OPENING PRESSURE TEST
temperature stamped on the thermostat. It should 1. Open the shutoff valve at the pressure gage
be fully open at approximately 13°C (24°F) above one-quarter turn.
the stamped temperature located on the thermo
stat. CAUTION: When testing nozzles, do not place
2. Do not attempt to repair the thermostat. If the your hands or arms near the top of the noz
thermostat does not function properly, replace it zle. The high pressure atomized fuel spray
with a new unit which has been checked as direct from a nozzle has sufficient penetrating pow
ed previously. er to puncture flesh and destroy tissue and
may result in blood poisoning. The nozzle tip
INJECTION NOZZLE TESTS should always be enclosed in a receptacle
Tool Required: preferably transparent, to contain the spray.
J 29075-B Nozzle Tester
J 29079-125 Adapter Kit 2. Depress the tester lever slowly. Note at what pres
J 29079-1 Line Assembly sure the needle of the pressure gage stopped. The
J 29079-3 Adaptor Nut maximum observed pressure is the opening pres
J 29079-18 Adaptor sure.
J 29079-13 Manifold Adaptor
J 7660-101 Washer • Some nozzles may pop while other nozzles
Nozzle testing is comprised of the following checks: may drip down. This is not leakage.
• Nozzle opening pressure 3. The opening pressure should not fall below the
• Leakage lower limit of 105 bar (1500 psi) on used nozzles
• Chatter on 6.5L engines and 120 bar (1750 psi) on 6.5L
•Spray pattern turbocharged engines.
Each test should be considered independent of the 4. Replace nozzles which fall below the lower limit.
others. For example, when checking opening pressure,
do not check for leakage. LEAKAGE TEST
If all of the above checks are okay, the nozzle holder 1. Further open the shutoff valve at the pressure gage
assembly can be reused. If any one of the checks is (1/2 to 1 1/2 turns).
not okay, the complete nozzle holder assembly must be 2. Blow-dry the nozzle tip.
6.5L DIESEL 6A7-23
CAUTION: When testing nozzles, do not place INJECTION PUMP

your hands or arms near the top of the noz
zle. The high pressure atomized fuel spray
I9 Inspect
from a nozzle has sufficient penetrating pow
er to puncture flesh and destroy tissue and
may result in blood poisoning. The nozzle tip • Injection pump body and mounting flange for dam
should always be enclosed in a receptacle age.
preferably transparent, to contain the spray. • Injection pump for evidence of fuel leakage.
• Injection line fittings for stripping.
3. Depress the lever of the manual test stand slowly
until the gage reads a pressure of 95 bar (1400
INJECTION PUMP REPAIR
psi). Observe the nozzle tip. A drop may form on Refer to the SECTION 6C2 in the proper service
the end of the nozzle but should not drop off within manual for allowable repairs. If necessary, have the
a period of 10 seconds. pump repaired by an authorized repair station.
4. Replace the nozzle assembly if a drop falls during
the 10 seconds.
CHATTER TEST
When testing for chatter, it should be noted that the CLEANING AND INSPECTION
sound (chatter) for new and used nozzles may vary.
This is due to carbonized fuel deposits on the pintle IQ i Clean
and nozzle tip of used nozzles. With some used noz
zles, chatter is difficult to detect during slow actuation of A. Crankshaft with solvent.
the hand lever.
• Do not scratch the bearing journals.
Some nozzles may chatter louder than others. As
• Blow all sludge from the oil passages with com
long as there is chatter, the nozzle is acceptable.
pressed air. Wear protective safety glasses and
1. Close the shutoff lever at the pressure gage. gloves.
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).
INJECTION LINES • Mount the crankshaft in V-blocks or between

centers.
1? Inspect • Use a dial indicator as shown.
• If runout exceeds 0.01 mm (0.0004 inches), the
Injection lines for kinks and damaged fittings. crankshaft is bent and must be replaced, along
Replace any damaged lines. with the main bearings.
6A7-24 6.5L DIESEL
FLYWHEEL
Clean
Mating surfaces of crankshaft and flywheel.

Remove any burrs.
i? Inspect
Flywheel for burning, scoring, warping, and wear.

Replace the flywheel if necessary. Do not machine
the flywheel.
Flywheel ring gear for worn or broken teeth.
TORSIONAL DAMPER
I? Inspect
Oil seal contact area on the torsional damper shaft

for grooving and roughness. Replace if necessary.
NOTICE: The main bearing and crankpin jour Always replace torsional damper if crankshaft
nals are m achined with deep, rolled fillets for breakage occurs.
strength. Do not grind the crankshaft since
the fillets m ay be disturbed and the crank
shaft weakened. If the crankshaft is dam aged
in any way it m u st be replaced.
NOTICE: If the timing chain, timing gears,
fro n t cover, c r a n k sh a ft p o s itio n se n so r,
crankshaft or other com ponent(s) affecting
timing are replaced, it will be n ecessa ry to
reprogram TDC O ffset into the PCM. Refer to
Electrical Diagnosis Manual. (L49 VIN P, L56
B4523
Figure 47—Checking the Crankshaft Run-Out

6.5L DIESEL 6A7-25

CAMSHAFT INSTALLATION three sizes and stamped #1, #2, or #3 on the pan rail.
The crankshaft is color marked red/orange, blue, or
“►+ Install or Connect (Figure 48) white near the main bearing journal. The proper bearing
selection is made by using the number on the pan rail
• When a new camshaft is installed, replacement of and cross referencing it with the color on the crank
shaft.
all hydraulic lifters, engine oil, and oil filter is rec
ommended. A chart for selecting the proper bearing halves is
shown in the crankshaft main bearing specifications at
1. Key.
the rear of this section.
2. Spacer, with the ID chamfer towards the camshaft.
3. Camshaft (figure 48). Main Bearing Selection for Service
• Coat the camshaft lobes with “Molykote” or
equivalent. • Main bearings are available in Standard, 0.013-mm
• Lubricate the camshaft bearing journals with (0.0005-inch) and 0.026-mm (0.001-inch) under
engine oil. sizes for select fitting to attain proper main bearing
• Insert the camshaft carefully into the block to clearance. “Undersize” refers to the crankshaft
avoid damage to the camshaft bearings. diameter.”
4. Thrust plate and bolts. • For service purposes, bearing size combinations
that provide the following clearance, as measured
Tighten with the plastigage procedure. Refer to SECTION
6A.
• Bolts to 23 N-m (17 lbs. ft.). A. Main Bearing #1, #2, #3, and #4: 0.045 to 0.083
mm (0.0018 to 0.0033 inches).
CRANKSHAFT INSTALLATION B. Main Bearing #5: 0.055 to 0.093 mm (0.0022 to
0.0037
AVAILABLE BEARING SIZES
inches).
Factory Main Bearing Selection
There are five main bearings numbered 1 through 5 -►+ Install or Connect (Figures 49 and 50)
from the front of the engine. There is an arrow on the
bearing cap that points toward the front of the engine. 1. Upper main bearing inserts to the block.
The center number 3 bearing is the thrust bearing. The 2. Crankshaft.
upper bearing halves have an oil groove. The lower 3. Lower main bearing inserts to the main bearing
bearing halves do not have an oil groove. caps.
During factory assembly the main bearings are
select-fitted to each of the five main bearing bores. The Measure
proper size code is stamped on the pan rail at the
corresponding main bearing bulk head. The total diame
• Main bearing clearance. Refer to SECTION 6A.
ter size range of the main bearing bores 1 through 5 is
79.826 mm to 79.850 mm. This range is divided into 4. Apply engine oil to the main bearings.
Figure 48— Camshaft and Components Figure 49—Crankshaft and Components

6A7-26 6.5L DIESEL
NOTICE: The main bearing caps are to be 1? Inspect

tapped into place with a brass or leather mal
let before the attaching bolts are installed. Do Crankshaft for binding. Try turning the crankshaft to
not use the attaching bolts to pull the main check for binding. If the crankshaft does not turn
bearing c a p s in to their s e a ts , a s th is m a y freely, loosen the main bearing cap bolts, one pair
damage the bearing cap and/or block. at a time, until the tight bearing is located. Burrs on
5. Number 5 (rear) main bearing cap. the bearing cap, foreign matter between the insert
A. Apply RTV to ends of rear main seal in rear and the block or the bearing cap, or a faulty insert
main bearing cap. could cause a lack of clearance at the bearing.
B. Apply engine oil to the main bearing cap bolt
threads. TIM ING CHAIN AND
C. Tap the main bearing cap into place with a
brass or leather mallet. Then install the bolts.
SPROCKET INSTALLATION
Tighten -►+ Install or Connect (Figure 51)
• 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.
• Bolts to specifications. Refer to step 5. Tighten

7. Number 3 (center) main bearing cap and bolts.
Tighten the bolts temporarily to 14 N-m (10 lbs. ft.).
Bolt to 100 N-m (75 lbs. ft.).
Measure (Figure 50)
Measure
A. Tap the end of the crankshaft first rearward then Timing chain free play as follows:
forward with a lead hammer. This will line up
the main bearing and crankshaft thrust sur 1. Mount a dial indicator to the front of the block.
faces. 2. Position the dial indicator so that the plunger
B. Tighten the main bearing cap bolts to specifica contacts the timing chain between the two
tions. Refer to step 5. sprockets.
C. With the crankshaft forced forward, measure at 3. Pull the chain outward (parallel to the front face
the front end of the number 3 main bearing with of the block) the maximum amount with finger
a feeler gage (figure 50). The proper clearance pressure on the inside of the chain.
is 0.10-0.25 mm. 4. Set the dial indicator to zero.
6.5L DIESEL 6A7-27
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
Electrical Diagnosis Manual. (L49 VIN P, L56

y| Clean
• Sealing surfaces on the block and front cover with

carburetor cleaner or equivalent.
I? Inspect
Torsional damper hub sealing surface for dam

age. Replace if necessary.
+4- Install or Connect (Figure 52)
• Apply a 2-mm (3/32-inch) bead of anaerobic

sealant (GM P/N 1052357) or equivalent to the
front cover sealing area shown in figure 53.
1. Front cover to the engine. Install the bolts.
Tighten

2. Crankshaft sensor with new O-ring seal.
a Tighten
• Retaining bolt to 25 N-m (17 lbs. ft.).
Important
• (L57 only) If new front cover was installed mark

TDC on the new cover as outlined under "Mark
ing TDC on Front Cover".
TORSIONAL DAMPER
INSTALLATION
Install or Connect
Before installing the torsional damper, check oil

seal contact area for grooving and roughness.
Replace damper if necessary. Figure 53—Applying Sealer to Front Cover
6A7-28 6.5L DIESEL
NOTICE: If the timing chain, timing gears, Tighten

fro n t cover, c ra n k sh a ft p o sitio n se n so r,
crankshaft or other com ponent(s) affecting Clamp bolts to 26 N-m (18 lbs. ft.).
timing are replaced, it will be n ecessa ry to
reprogram TDC O ffset into the PCM. Refer to Important
Electrical Diagnosis Manual. (L49 VIN P, L56 »After all clamps are installed, turn the crank
VIN S, L65 VIN F only) shaft by hand 720 degrees (two full turns), to
insure free movement of the lifters in the guide
HYDRAULIC LIFTER plates. If the engine will not turn over by hand,
one or more of the lifters may be binding in
INSTALLATION their guide plates.
Important CONNECTING ROD AND

• When installing a new camshaft the lifters must be PISTON INSTALLATION
replaced. CONNECTING ROD BEARINGS
• Some engines will have both standard and
0.010-inch oversize hydraulic lifters. The oversize Connecting rod bearings are of the precision insert
lifter will have a “10” etched on the side. The block type and do not use shims for adjustment. DO NOT
will be stamped “O.S.” on the cast pad adjacent to FILE RODS OR ROD CAPS. If clearances are exces
the lifter bore and on the top rail of the cylinder sive, install a new bearing. Service bearings are avail
case above the lifter bore. able in standard size (Yellow color identification), and
0.026 mm (0.001-inch) undersize (green color identifica
Install or Connect (Figure 54) tion).
is necessary to obtain close tolerances. For this reason
NOTICE: N ew h y d ra u lic lifte r s m u s t b e you may use, for example, one half of a standard insert
prim ed before installation. Damage to the lift with one half of a 0.026-mm (0.001-inch) undersize
ers m ay resu lt if th e y are dry w hen the insert which will decrease the clearance 0.013 mm
engine is started. (0.0005 inch) from using a full standard bearing.
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
+«- Install or Connect (Figures 55, 56, and 57)
Tool Required:
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
Piston and connecting rod to the proper bore.

two short pieces of 10 mm ( 3/8-inch) hose onto
the connecting rod studs.(Figure 56)
B. Locate the piston ring end gaps, piston viewed
with swirl indent up.
• Oil Ring Expander Gap at 45° left of swirl
indent.
• Oil Control Ring Gaps 180°(0pposite) of Oil
Expander ring.
• Second Compression Ring gap at piston
top(under swirl indent).
• First Compression Ring 180°(0pposite) Sec
ond Ring. Lubricate the piston and rings
with engine oil.
C. Without disturbing the ring end gap location,
install J 8037 over the piston (figure 55).
D. The piston must be installed so that the depres
sion in the piston crown is towards the outside
of the engine.
E. Place the piston in its matching bore. Using
light blows with a hammer handle, tap the pis Rod
ton down into its bore (figure 55). At the same
time, from beneath the engine, guide the con
necting rod to the journal with the pieces of
hose (figure 56). Hold the ring compressor
against the block until all rings have entered the
cylinder bore.
F. Remove the hoses from the connecting rod
bolts.
Important
• Each connecting rod and bearing cap

should be marked, beginning at the front of
the engine. Cylinders 1, 3, 5, and 7 are the
left bank and, 2, 4, 6, and 8 are the right
bank. The numbers on the connecting rod
when installed in the cylinder bore. If a con
necting rod is ever transposed from one
block or cylinder to another, new connecting
rod bearings should be fitted and the con
necting rod should be numbered to corre
spond with the new cylinder number. MARKING TDC ON THE FRONT COVER (L57 only)
% Measure Measure TDC On Front Cover (Figures 58, 59,

and 60)
• Connecting rod bearing clearance. Refer to
SECTION 6A. Tool Required:
3. Apply engine oil to the connecting rod bearings. J 33042 Timing Fixture
4. Connecting rod cap with bearing. 1. Set the engine so that number 1 cylinder is at TDC
5. Connecting rod cap nuts. (firing).
2. Install J 33042 in the injection pump location (fig
Tighten ure 58).
&
• Do not use the gasket.
• Connecting rod cap nuts to 65 N-m (48 lbs. ft.). 3. Set the injection pump gear (figure 59) in place,
aligning the timing marks on the injection pump
€ Measure Clearance (Figure 57) and camshaft gears as shown. The slot in the
injection pump gear should be in the vertical 6
• Connecting rod side clearance. Use a feeler o’clock position (figure 60). If not, remove J 33042
gage between the connecting rod and crank and rotate the engine crankshaft 360 degrees.
shaft (figure 57). The correct clearance is 4. Fasten J 33042 to the injection pump gear and
0.17-0.63 mm. tighten (figure 58).
6A7-30 6.5L DIESEL
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.
OIL PUMP INSTALLATION

1. Oil pump with extension.

2. Bolt.
& Tighten
J 33042 Bolt to 90 N-m (65 lbs. ft.).

-►+ Install or Connect (Figure 62)
• Apply a 5-mm (3/16-inch) bead of RTV sealant

(GM P/N 12345739) to the oil pan sealing surface,
inboard of the bolt holes. The sealer must be wet
to the touch when the oil pan is installed.
1. Oil pan rear seal to the oil pan.
2. Oil pan to the engine.
3. Bolts.
m Tighten
A. All except rear two bolts to 10 N-m (89 in. lbs.).

Figure 58—Marking TDC on the Front Cover B. Rear two bolts to 23 N-m (17 lbs. ft.).
6.5L DIESEL 6A7-31
Figure 63— Head Bolt Tightening Sequence
Figure 62—Oil Pan Figure 64— Cylinder Head and Components

dowel pins.
CYLINDER HEAD 3. Head bolts.
INSTALLATION A. Make sure the bolt threads are clean.
B. Apply thread sealant (GM P/N 9985283) or
equivalent to the bolt threads and under the bolt
heads.
Tool Required:
Tighten
1. Head gasket to the block, over the dowel pins.
Important A. Head bolts.

B. Using the sequence shown in figure 63,
• The block gasket surfaces must be clean. tighten all bolts to 25 N-m (20 lbs. ft.).
• DO NOT use a sealer on the head gasket. The C. In sequence, tighten all bolts to 65 N-m (50
head gasket is manufactured with sealant on its lbs. ft.).
surface. Additional sealer may cause leakage or D. Repeat step C.
malfunction. In addition, some sealers may E. In sequence, tighten all bolts an additional
attack the sealant already on the head gasket. 90 to 100 degrees (1/4 plus turn).
2. Cylinder head. Make sure the gasket surfaces are
4. J 29664-1 to the intake ports.
clean. Guide the head carefully into place over the
6A7-32 6.5L DIESEL
Figure 65—Rocker Arms Figure 66—Applying Sealant to the Rocker Cover
PUSHROD AND ROCKER ARM Install or Connect (Figure 66)

INSTALLATION
NOTICE: Do not allow RTV sealant into the
install or Connect (Figures 65 and 66) rocker arm cover bolt holes. This m ay cause
a “hydraulic lock” condition when the bolts
NOTICE: The pushrods m u st be installed with are tightened , dam aging the cylinder head
the m arked or painted en d up. Failure to do casting.
so m ay result in damage or premature wear. • Apply a 5-mm (3/16-inch) bead of RTV sealant
(GM P/N 12345739) to the rocker arm covers,
1. Pushrods, with the painted or marked end up.
inboard of the bolt holes. Refer to figure 66. The
2. Rocker arm shaft assembly. Make sure the ball
sealer must be wet to the touch when the bolts are
ends of the pushrods seat in the rocker arms.
tightened.
NOTICE: Improper installation o f the rocker 1. Rocker arm covers.
arm shaft bolts m ay cause rocker arm shaft 2. Rocker arm cover bolts.
breakage and/or piston to valve contact.
Tighten
3. Bolts.
A. Rotate the engine until the mark on the torsion • Rocker arm cover bolts to 22 N m (16 lbs. ft.).
al damper aligns with the “0” mark on the tim
ing tab. INJECTION PUMP
B. Rotate the engine counterclockwise 88 mm (3
1/2 inches), measured at the torsional damper.
INSTALLATION
This measurement can be estimated by aligning +<- Install or Connect (Figure 67 and 68)
the torsional damper mark with the first lower
coolant pump bolt. This procedure will position 1. Gasket to the front cover.
the engine so no valves are close to a piston 2. Injection pump.
crown. 3. Throttle spring bracket (if equipped).
C. Install the bolts finger tight. 4. Nuts. Leave finger tight until the injection pump
timing is adjusted.
Tighten
5. Injection pump gear. Align the slot in the injection
pump gear with the locating pin on the injection
• Bolts alternately to 55 N-m (40 lbs. ft.). Rotate
pump hub.
(bar) engine by hand to ensure free movement
of the valve train. Important
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
NOTICE: R efer to appropriate D riveability

Em issions and Electrical Diagnosis Manual to
s e t pum p timing on L49 Vin P, L56 VIN S, and
L65 VIN F.
COOLANT PUMP INSTALLATION

Py| Clean
• Sealing surfaces on the coolant pump plate and

block. Use carburetor cleaner or equivalent.
Install or Connect (Figures 69, 70 and 71)
1. Coolant pump and gasket to the coolant pump

plate.
2. Bolts.
• Apply high temperature thread adhesive (GM
12345493) or equivalent to bolt threads.
Figure 67—Injection Pump
Figure 69—Coolant Pump Mounting

Figure 68— Injection Pump Gears
6. Bolts(lnjection Pump Gear).
Tighten
• Bolts to 25 N.m (20 lbs. ft.).

7. Wires and hoses at the injection pump.
Adjust
(L57 only) Injection pump timing. For the engine to

be properly timed, the marks on the top of the
engine front cover must be aligned with the marks
on the injection pump flange. The engine must be
off when the timing is set.
$ 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
-►4* Install or Connect (Figures 74 and 75)
1. Thermostat.
2. Gasket
3. Thermostat housing.
4. Bolts/Studs
Tighten
• Bolts/Studs to 47 N-m (35 lbs. ft.)

5. Fuel filter water drain valve bracket and nut.
Figure 72—Coolant Crossover (C/K Models)
6.5L DIESEL 6A7-35
Figure 74—Thermostat and Housing (G and P Figure 76—Oil Filler Neck

Models)
EXHAUST MANIFOLD
INSTALLATION
44- Install or Connect (Figures 77, 78, and 79)
Exhaust manifolds and bolts.
Tighten
GLOW PLUG INSTALLATION

+ 4- install or Connect (Figure 80)
Glow plugs.
Tighten
Glow plugs to 18 N-m (13 lbs. ft.).

Figure 75—Thermostat and Housing (C/K Models)
OIL FILLER NECK

INSTALLATION
Instaii or Connect (Figure 76)
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
1. New O-ring seal to the dipstick tube.

2. Dipstick tube to the engine.
3. Dipstick tube bracket bolt. Figure 77—Right Exhaust Manifold (Turbo)
6A7-36 6.5L DIESEL
Figure 78—Right Exhaust Manifold Figure 80—Glow Plugs
RETURN LINE INSTALLATION

+«- Install or Connect (Figure 81)
1. Fuel return lines as an assembly.

2. Fuel return hose from the injection pump.
3. Fuel return line brackets on front left and right side
rocker covers.
4. Fuel return hoses at injector nozzles.
5. Clamps.
INJECTION LINE
INSTALLATION
+ 4- Install or Connect (Figure 82)
1. Injection line brackets.

2. Injection lines to the pump beginning from the bot
tom of the pump using the following sequence: Cyl
inders 4, 5, 3, 6, 1, 2, 8, 7. Do not bend the
injection lines.
Figure 79— Left Exhaust Manifold
INJECTION NOZZLE
INSTALLATION
Install or Connect
Tool Required:
J 29873 Nozzle Socket
NOTICE: When installing an injection nozzle,

u se J 29873. Install th e n o zzle u sin g the
30-mm h e x portion. Failure to do s o will
result in damage to the injection nozzle.
1. Injection nozzle with gasket using J 29873.
Tighten
• Nozzle to 80 N-m (59 lbs. ft.). Figure 81— Return Lines

6.5L DIESEL 6A7-37
Figure 84— Intake Manifold Left Side
3. Injection lines to the nozzles. Uncap the lines

before assembly. Do not bend the injection lines.
a Tighten
• Injection line fittings at both ends of the lines to

33 N-m (24 lbs. ft.).
4. Injection line clips to the brackets.
INTAKE MANIFOLD
INSTALLATION
J 29664-1 from the intake ports.
+«- Install or Connect (Figures 83,84 and 85)
Tool Required:
Figure 85—Intake Manifold Right Side
1. New gaskets. Be sure to use the correct gasket.

The gaskets for light duty emissions models have
openings for the EGR, the gaskets for heavy duty
emissions models do not.
2. Intake manifold.
3. Intake manifold bolts/studs and fuel line clips.
There are 4 bolts, numbers 9, 11, 13, and 15
exposed to the crankcase, and should be sealed
with teflon sealer (figure 83).
£ Tighten
• Intake manifold bolts/studs to 42 N-m (31 lbs.

ft.).Use the tightening sequence shown in figure
83.
4. J 29664-2 to the mouth of the intake manifold.
Figure 83—Intake Manifold Torque Sequence

6A7-38 6.5L DIESEL
OIL PUMP DRIVE INSTALLATION ENGINE ACCESSORY

INSTALLATION
NOTICE: Do not run the engine without the Install the engine accessories as directed in the prop
oil p u m p drive in place. This will ca u se er Truck Service Manual. Connect all vacuum hoses
extensive engine damage. and electrical equipment the same way as removed.
Install or Connect (Figures 86 and 87) REAR CRANKSHAFT OIL

SEAL INSTALLATION
1. New gasket to the oil pump drive.
2. Oil pump drive to the engine. Index the drive or Install or Connect (Figure 88)
pump with the camshaft gear and oil pump drive
shaft. Make sure the drive or pump seats fully. Tool Required:
3. Clamp and bolt. J 39084 Rear Crankshaft Seal Installer
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
ENGINE SETUP AND TESTING

1. After overhaul, the engine should be tested before
installation in the vehicle. If a suitable test stand is
Figure 86—Oil Pump Drive not available, the following procedure can be used
after the engine is installed in the vehicle.
Figure 87—Oil Pump Drive(Left L57, Right EFI

Engines) Figure 88—Rear Main Seal Installation
6.5L DIESEL 6A 7-39

grade of oil and install a new oil filter. Refer to
SECTION OB. Replacement of the engine oil and
filter is recommended, especially if a new camshaft
was installed.
3. Fill the cooling system with the proper coolant.
4. With the shutdown solenoid disconnected, crank
the engine several times. Listen for any unusual
noises or evidence that any parts are binding.
5. Start the engine and listen for unusual noises. Run
the engine at about 1000 rpm until the engine is at
operating temperature.
Listen for sticking lifters, and other unusual
noises. Check for oil and coolant leaks while the
engine is running.
(L57 only) Using the Emission Control Label for
specifications, adjust idle speed, fast idle speed,
etc. as required.
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
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
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
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
ENGINE SPECIFICATIONS (CONT.)

AH Specifications are in millimeters (mm) unless otherwise noted.
DISPLACEMENT | 6.5L
CAMSHAFT:
Intake 7.133
Lobe Lift ± 0.05
Exhaust 7.133
#1, #2, #3, #4 54.970-55.025
Journal Diameter
#5 50.970-51.025
Journal Clearance #1 , #2, #3, #4 0.025-0.118
Journal Clearance #5 0.020-0.113
Camshaft End Play 0.051-0.305
VALVE SYSTEM:
Lifter Hydraulic Roller
Intake
Valve Lash Not Adjustable
Exhaust
Valve Protrusion (Negative because valve is Intake -.034
recessed in head) Exhaust -.048
pb a | / 1 1 1 A p* | .V . r o
Face Angle (Intake & Exhaust) 45
o@3t Angle (Intake & Exhaust) 46
beat Hunout (intak© & exhaust) 0.05
Intake 0.89-1.53
Seat Width
Exhaust 1.57-2.36
Intake 0.026-0.069
Stem Clearance
Exhaust 0.026-0.069
Pressure Closed 356 N @ 46.0 mm
Valve Spring Newtons @ mm Open 1025 N @ 35.3 mm
Installed Height 46
New Chain 12.7 mm (0.500-inch)
McpH Chain ?0 3 mm ^0 ftOO-inrh^
T2843
1995 6.5L DIESEL ENGINE

PRODUCTION AND SERVICE PISTON — CYLINDER BORE
SPECIFICATIONS
Note: Cylinders #7 and #8 require 0.013m m (0.0005" additional piston to bore clearance.
ENGINE PISTON SKIRT DIAMETER BORE DIAMETER BORE DIAMETER
DISPLACEMENT GRADE 1 THRU 6 7 & 8
6.5L Production Std. 102.865-102.883 mm 102.972-102.990 mm 102.985-103.003 mm
— JT or JT
Production Rewk. 103.008-103.026 mm 103.117-103.130 mm 103.130-103.143 mm
— S or ST
Service Std.— JT 102.865-102.883 mm 102.972-102.990 mm 102.985-103.003 mm
Service Hi Limit— GT 102.904-102.922 mm 103.013-103.026 mm 103.026-103.039 mm
Service 0.50mm OS 103.399-103.417 mm 103.508-103.512 mm 103.521-103.525 mm
— 0 50 OST
All 1995 6.5L Diesel Engines (turbocharged and naturally aspirated) are serviced with “T” pistons (i.e. “JT”,
“GT”, or “0.50 OST”)..
T3032
6A7-42 6.5L DIESEL
CRANKSHAFT MAIN BEARING SELECTION AND SPECIFICATIONS

6.5L ENGINES
CRANKSHAFT MAIN JOURNAL CYLINDER & CASE
DIAMETERS MAIN BEARING BORE DIAMETERS
#1 TO #4 #5 79.850 79.842 79.834
79.842 79.834 79.826
STAMP 3 STAMP 2 STAMP 1
74.917 74.912 1-.026 U.S. IN CASE 1-.013 U.S. IN CASE 1-STD IN CASE
74.925 74.920 1-.026 U.S. IN CAP 1-.026 U.S. IN CAP 1-.026 U.S. IN CAP
BLUE BLUE
74.925 74.920 1-.026 U.S. IN CASE 1-.013 U.S. IN CASE 1-STD IN CASE
74.933 74.928 1-.013 U.S. IN CAP 1-.013 U.S. IN CAP 1-.013 U.S. IN CAP
ORANGE OR RED ORANGE OR RED
74.933 74.928 1-.026 U.S. IN CASE 1-.013 U.S. IN CASE 1-STD CASE
74.942 74.936 1-STD IN CAP 1-STD IN CAP 1-STD IN CAP
WHITE WHITE
T3031
CASE, CAMSHAFT AND CAMSHAFT BEARINGS (mm)

SPECIFICATIONS
6.5L ENGINES
#1 #2 #3 #4 #5
Camshaft Journal Diameter O.D. 55.025 55.025 55.025 55.025 51.025
(Diameter Tolerance .055mm 54.970 54.970 54.970 54.970 50.970
Finished Cam Bearing I.D. 55.088 55.088 55.088 55.088 51.083
(Diameter Tolerance .038mm 55.050 55.050 55.050 55.050 51.045
.118 .118 .118 .118 .113
Camshaft Bearing Clearance .025 .025 .025 .025 .020
59.17 58.92 58.67 58.42 50.42
Cam Bore Diameter (Case) 59.12 58.87 58.62 58.37 50.37
59.30 59.05 58.80 58.55 50.55
Cam Bearing O.D. 59.25 59.00 58.75 58.50 50.50
^ o
OOIOO
■Îq
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
CRANKSHAFT PIN JOURNALS AND CONNECTING ROD BEARINGS

CRANKSHAFT PIN CONNECTING ROD ROD & CAP BEARINGS CONNECTING ROD I.D.
JOURNAL DIAMETER BEARINGS COLOR CODES
60.913mm Standard in Rod .026 U.S. 64.150mm
60.926mm Green .026 U.S. in Cap (Green) 64.124mm
60.926mm Standard in Rod Standard
60.939mm Yellow Standard in Cap (Yellow)
CONNECTING ROD TO CRANKSHAFT JOURNAL BEARING CLEAR

ANCE
CALCULATED CLEARANCE ‘ ACTUAL CLEARANCE
.035mm .0014" .045mm .0018"
.090mm .0035" .100mm .0039"
‘ Actual clearance based upon estimated bearing distortion of 0.01mm.
T3033
6.5L DIESEL 6A7-43
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
MODEL 220 TBI UNIT

For information about the TBI fuel system refer to the appropriate Driveability, Emissions, and Electrical Diagnosis
Manual.
--------------
---------------------------- ■
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- %‘ ■■■
3TM3TMOO- .w•: :•>« 'v -
* >,'139
* • a I* » '« « •« « \ . it dbioM mftBlZ Tfc :*s

....ristiw? &gpfjpY 5 -
•■V-C-
........
'
V-Xi;A1 W.
.
SD STARTER MOTORS 6D2A-1
SECTION 6D2A
SD STARTER MOTORS
the correct part num ber fastener is not available, a fastener o f equal size and strength (or stronger) m ay
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.
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.
DISASSEMBLY OF THE SD -210 AND

SD -260 STARTER MOTORS
If the motor does not perform to specifications, it may FRAME AND FIELD ASSEMBLY
need to be disassembled for further testing of the com
ponents. Normally, the starter motor should be disas Disassemble (Figure 3)
sembled only so far as is necessary to make repair or
replacement of parts. As a precaution, it is suggested 1. Through-bolts from the end frame.
that safety glasses be worn when disassembling or 2. End frame.
assembling the starter motor. 3. Brake washer from the armature assembly.
Before disassembly, perform the electrical tests on 4. Frame and field assembly from the armature/drive
the solenoid described under “Inspection and Repair” end frame assembly.
later in this section.
SOLENOID DRIVE END FRAME ASSEMBLY

❖ Disassemble (Figure 3)
1. Plug from the drive end frame assembly.
A. Clean the outside of the starter housing.
2. Armature with the drive assembly, shift lever,
• Remove grease, oil, mud, etc. plunger and return spring from the drive end frame.
3. Return spring from the plunger.
B. Make scribe marks to show the relationship of the
4. Plunger from the shift lever.
drive end frame, frame and field assembly, and the
5. Shift lever from the drive assembly by spreading
end frame to aid in assembly.
the lever arms slightly to snap them off the mating
C. Note the position of the through-bolts.
buttons on the drive collar.
• One has a stud on the end. 6. Drive assembly from the armature shaft as follows:
Models with Solenoid Shield: A. Remove the thrust collar from the armature
shaft.
1. Solenoid shield nuts from the solenoid clamp B. Drive the pinion stop collar away from the pin
screws. ion stop retainer ring by sliding a metal cylinder
2. Shield from the solenoid. onto the armature shaft and with a hammer,
3. Motor lead attaching nut and lead from the sole strike the metal cylinder against the stop collar.
noid. C. Spread the pinion stop retainer ring to remove it
4. Solenoid clamp attaching screws, clamp, and sole from the groove in the armature shaft. Discard
noid from the frame assembly. the old ring. The retainer ring must be replaced.
D. Slide the stop collar and drive assembly off the
armature shaft.
Figure 4—Armature, Drive, and Shift Lever

Figure 3—SD-210 and SD-260 Components Assembly
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
12. Field coils for opens.

• Connect a self-powered test lamp between the
field connector and each of the positive
brushes.
— If the test lamp does not light at both
brushes, the field coils are open.
13. Field coils for shorts.

• Shorts are indicated by poor motor performance
after everything else has been checked out.
The coils cannot be replaced separately
because of the integral frame construction. The
frame and field assembly must be replaced.
14. Drive assembly (clutch) by turning the drive pinion
in the cranking direction.
• If the drive pinion turns roughly or slips in the
cranking direction, replace the complete
over-running clutch assembly.
Grounds
15. Solenoid for grounds using a self-powered 12 volt
test lamp (figure 7).
A. Connect the test lamp between the BAT termi
nal and the case. The lamp should not light
(terminal should not be grounded).
B. Connect the test lamp between the “S” terminal
and the case. Then connect the test lamp
between the “M” terminal and “S” terminal or
“M” terminal and the case. The lamp should
light.
C. If the solenoid does not pass these checks,
replace it.
16. Hold-in winding and pull-in winding.
A. If solenoid is not removed from starter motor,
the field lead must be removed from the termi
nal on the solenoid before making these tests.
Make test connections as shown in figure 8.
NOTICE: To prevent overheating the pull-in Figure 8—Solenoid Test Connections

winding, do not leave the winding energized
m ore than 15 seconds. The current draw will C. Note the ampere reading. A high reading indi
d e c r e a s e a s th e w in d in g te m p e r a tu r e cates a shorted or grounded winding, and a low
increases. reading indicates excessive resistance.
• The resistance of the windings can be read
B. To check both windings, connect an ammeter in directly using a digital ohmmeter that can
series with 12-volt battery and the “switch” ter measure tenths of an ohm.
minal on the solenoid. Connect a voltmeter to • Coil resistance can be determined by divid
ing the voltage by the current (amperes) list
the “switch” terminal and to ground. Connect
ed in “Specifications” at the end of this
carbon pile across battery. Ground the solenoid
section.
motor terminal. Adjust the voltage to 10 volts
and note the ammeter reading. It should be 60
to 85 amperes.
ASSEMBLY OF THE SD -210 AND SD -260

STARTER MOTORS
DRIVE END 7. Plunger to the lever by snapping into place. Note
which side of the lever is up (figure 4).
* Assemble (Figures 4, 9, and 10) 8. Armature shaft into the drive end bearing while
sliding the shift lever retainer into the slot on the
• Wipe the armature shaft clean and lubricate the drive end housing.
area that will be under the drive assembly. Use 9. Spring onto the plunger.
Delco-Remy Lubricant DC 33 or equivalent. 10. Plug.
• Wipe the drive assembly clean. 11. Solenoid and clamp onto the drive end frame,
1. Drive assembly onto the armature shaft. aligning the “M” terminal with the field connector.
2. Pinion stop collar with the flat side of the collar 12. Clamp retaining screws.
toward the drive pinion.
3. New retaining ring onto the armature shaft. NOTICE: Refer to “N otice” on page 6D2A-1.
• Slide the ring down the shaft until it seats in the
shaft groove.
4. Thrust collar onto the shaft with the small flange
& Tighten
toward the retaining ring. • Solenoid clamp retaining screws to 11 N m (95

• Using two sets of pliers, push the pinion stop lbs. in.).
collar and thrust collar together to snap the stop
collar onto the retaining ring (figure 10). FRAME AND FIELD ASSEMBLY
1? Inspect SD-210
* Assemble (Figure 3)
Drive end bushing. If no lubrication is visible,
lubricate it with DC 33 grease. Avoid excessive
grease. If the bushing is damaged, replace the
tice” on page 6D2A-1.
drive end frame.
Inspect SD-260 1. Frame and field assembly onto the armature.

L*
A. Clean the contact faces of the brushes and the
• Drive end bearing. If no lubrication is visible, commutator with a soft cloth.
replace the bearing using a suitable driver and B. Push the brushes into the brush holders and
hammer. Do not lubricate the bearing. hold them in place while installing the frame.
5. New drive end bearing by pressing it in until it is C. Align the scribe mark on the frame with the
recessed 1.6 mm (0.06-inch) into the casing. It is scribe mark on the drive end frame.
prelubricated, so do not add lubricant. D. Release the brushes onto the commutator,
6. Shift lever to the drive assembly by spreading the making sure all four brushes move freely and
arms slightly to snap it onto the buttons on the contact the commutator.
drive collar.
Figure 10— Forcing the Collar over the Retaining

Ring
2. Brake washer to the armature assembly.

3. Drain tube to the frame, if it was removed.
4. End frame to the field frame.
• If the end frame bearing shows no lubrication or
looks damaged, replace it by drawing it out.
• Recess the new bearing 2 mm (0.08-inch) into
the housing.
• The bearing is pre-lubricated. Do not add lubri
cant.
5. Identification tag over the hole in the end frame
with the fluted end around the bearing well.
6. Through-bolts in their original locations.
a Tighten
• Through-bolts to 8.5 N-m (75 lbs. in.).

7. Motor field lead over the motor terminal on the
solenoid.
8. Field lead attaching nut.
$ Tighten
• Field lead attaching nut to 11 N m (95 lbs. in.).

9. Solenoid shield onto the protruding ends of the
solenoid attachment screws.
10. Shield attaching nuts.
a Tighten
• Shield attaching nuts to 8 N m (70 lbs. in.).
PINION CLEARANCE CHECK

The pinion clearance should be checked after reas
sembly of the motor. It cannot be adjusted. Improper
clearance is an indication of worn parts.
To check pinion clearance, perform the following
steps (figures 11 and 12).
1. Disconnect the motor field connector from the sole
noid “M” terminal and insulate it carefully.
2. Connect a battery of the same voltage as the sole 4. Push the pinion back toward the commutator end
noid from the solenoid switch terminal to the sole to eliminate stack movement.
noid frame, 5. Measure the distance between pinion and pinion
3. Momentarily flash a jumper lead from the solenoid stop collar (figure 12).
motor terminal to the solenoid frame. This will shift
the pinion into cranking position and it will remain • Clearance should be 0.25 mm to 4.06 mm
so until the battery is disconnected (figure 11). (0.010 inch to 0.160 inch).
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

SD-210 and SD-260 Starter Motors: N-m Lbs. Ft. Lbs. In.
Field Lead Attaching Nut................................................................... 11 — 95
Shield Attaching Nuts........................................................................ 8 — 70
Solenoid Clamp Retaining Screws.................................................. 11 — 95
Through Bolts...................................................................................... 8.5 — 75
LUBRICATION
Use Delco-Remy DC 33 Lubricant or equivalent.
T2533
28-MT STARTER MOTORS 6D2B-1
SECTION 6D2B
28-MT STARTER MOTORS

be used. Fasteners that are n ot reused and those requiring thread locking com pound will be called out.
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.
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
Figure 3—28-MT Components

3. Grounded brush screws.

4. Brushes if they need replacement.
5. Brush springs if they need replacement.
• Grasp the brush end of each brush spring with
needle nose pliers. Twist the spring end away
from the brush and remove the brush.
All electrical components should be inspected and
tested. Refer to “Cleaning, Inspection, and Repair.”
GEAR REDUCTION AND DRIVE

GROUP
1. Housing bolts.
2. Armature support bracket.
9 Important
• Washers may stick to the bracket or to the

8. Solenoid assembly.
driveshaft and clutch group as the bracket is
• Pivot the inside end of the solenoid assembly removed. In either case, note the position and
out of engagement with the shift lever in the number of each of these washers.
gear reduction and drive group to withdraw it.
3. Washers.
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
screwdriver.
1. Insulated brush screws. 5. Shift lever nut, washer, and screw.

6. Shift lever and driveshaft and clutch group from the
• Move the brush holder assembly with brushes drive housing together, then separate them.
slightly away from the frame and field assembly
to reach across with a screwdriver and remove • Do not remove the bushing plug or bushing
from the drive housing unless replacement is
the screws.
necessary. Refer to “Cleaning, Inspection, and
2. Frame and field assembly. Repair.”
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.”

CLEANING Inspect (Figure 3)
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
5. Brush holder assembly (7) for the following.

Replace if damaged:
• Loose riveted joints.
• Cracked or broken insulation.
6. Brushes (5 and 8) for excessive wear.
•Minimum allowable brush length is 12 mm
(0.472 inch). Replace excessively worn brushes
in sets.
7. Drive end housing bushing (37) for scoring or other
damage. Replace the damaged bushing. Refer to
“Repair Procedures.”
8. Ball bearings (12, 14 and 32) as follows:
A. Hold the armature (13) or driveshaft (31) and
slowly rotate the outer bearing race by hand.
B. Check that the bearing turns freely without bind
ing or the feel of flat spots.
C. Replace damaged bearings. Refer to “Repair
Procedures.” Figure 9—Solenoid Terminals
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.
<-— 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).
Remove or Disconnect (Figures 3, 11, 12 and

13)
NOTICE: Ball bearings that are rem oved from

the arm ature m u s t be replaced with n ew
b earings. The rem o va l p ro ced u re c a u s e s
internal dam age to the bearings.
• Commutator and and/or drive end bearings (12 and

14) from the shaft of the armature (13) using a
suitable bearing puller.
Figure 13—Tool for Removing Center Support

Bearing (Installation View)
Install or Connect (Figures 3, 11, 12 and 13)
• New commutator end and/or drive end bearings

(12 and 14) to the armature assembly (13) using a
tube that bears on the bearing inner race only.
Press on the bearing until the inner race bottoms
out against the shoulder on the armature shaft.
CENTER SUPPORT BEARING
If necessary, replace the center support bearing (32)
on the driveshaft (31) as follows:
[♦--►I Remove or Disconnect (Figures 3, 11, 12 and

13)
NOTICE: Ball bearings that are rem oved from

th e arm ature m u s t b e replaced with n ew
Figure 11—Tool for Removing Center Support b earings. The rem o va l p ro ced u re c a u s e s
Bearing (Top View) internal damage to the bearings.
• 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)
• If the center support bearing (32) is being replaced,

install it on the driveshaft (31) as specified in “Re
pair Procedures,” step 2, before proceeding with
assembly.
-n - Install or Connect (Figures 3 and 14)
1. Driveshaft support (33) to the driveshaft (31), seat

ing the bearing (32) in the support.
2. Clutch drive assembly (34) to the driveshaft (31).
3. New pinion stop (36) and stop rings (35).
A. Slide the pinion stop (36) onto the driveshaft
(31). End with the recess for the stop rings fac
ing up.
B. Install the stop rings (35) into the groove in the
driveshaft.
C. Pick the assembly up and support it under the
pinion stop (36). A m etal block, with a
U-shaped cutout that will slide over the shaft
between the pinion gear and stop, can be
clamped in a vise to provide support (figure 14).
GEAR REDUCTION AND DRIVE

GROUP
Important (Figure 6)
If the drive end bushing and plug are being

replaced, install them in the drive housing as speci
fied in “Repair Procedures,” step 3, before pro
ceeding with assembly.
Lubricate the drive end housing bushing, shift
lever, and driveshaft as described in “Lubrication.”
NOTICE: For ste p s 3 and 7, refer to “NO

TICE” on page 6D2B-1.
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
• Shift lever nut to 4.5 N-m (40 lbs. in.).

4. Plate, if used, and drive housing plug to the drive
housing.
5. Washers in the same number and position as not
ed at disassembly.
6. Armature support bracket to the drive housing.
• Align the mark made prior to disassembly with
that on the drive housing.
7. Drive housing bolts.
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.
1. Brush springs if removed. A. Refer to figure 16 for proper installed position of

A. Start each brush spring onto the post on the all brushes. Make sure the insulated brushes go
brush holder assembly just enough to hold the into the brush sockets of the brush holder
inside end of spring from turning as shown in assembly that mounts on the insulation.
figure 15. B. To install each brush, grasp the free end of the
B. Grasp the free end of the spring with needle brush spring with needle nose pliers, twist it to
nose pliers and twist it to the right over the top the right to clear the brush socket, and insert
of the brush socket. the brush partly into the brush socket.
C. Gradually release the spring so that its end 1. Solenoid assembly.

contacts the side (not end) of the brush (figure A. Pivot the plunger of the solenoid assembly into
16). This will hold the brushes retracted until engagement with the shift lever in the gear
after the brush holder is installed over the reduction and drive group.
armature commutator. B. Position the solenoid assembly mounting flange
3. Grounded brush screws. and install the solenoid mounting screws.
A. Position the terminals of the grounded brush
leads behind the terminal tabs on the brush Tighten
holder (figure 16).
B. Insert the brush screws through the terminal • Solenoid screws to 2.8 N-m (25 lbs. in.).
tabs on the brush holder and thread into the 2. Frame seal.
brush lead terminals. 3. Armature assembly with bearings into the gear
reduction and drive group.
& Tighten
• Make sure the gear teeth are aligned, then seat
• Grounded brush screws to 1.5 N-m (13 lbs. in.). the bearing on the armature shaft fully into the
Frame and field assembly to the brush holder housing recess.
assembly (figure 5). 4. Frame, field, and brush holder group.
A. Position the brush holder assembly (with A. Place the dowel pin in the hole in the armature
installed brushes) over the terminal end of the support bracket of the gear reduction and drive
frame and field assembly. group.
B. Attach the terminals of the insulated brush B. Position the frame, field, and brush holder
leads to the conductors in the frame and field group over the armature assembly, align the
assembly with insulated brush screws. hole for the dowel pin and marks made prior to
disassembly, and seat in the gear reduction and
$ Tighten drive group.
C. Twist the brush springs away from the brushes,
• Insulated brush screws to 1.5 N-m (13 lbs. in.).
slide the brushes in to contact the commutator
UNIT ASSEMBLY on the armature, and release the brush springs
to contact the ends of the brushes (figure 5).
Support the gear reduction and drive group with the
pinion gear end down and proceed as follows (figures 4 • Brush spring tension should be 44.5 to
and 17). 49.nn (10-11 lbs. ft.). If not, replace the
springs before proceeding.
V Important 5. O-ring seal.
• If the armature bearings are being replaced, install Important

them on the armature as specified in “Repair Pro
cedures,” step 1, before proceeding with assembly. • The O-ring seal can easily be damaged during
■‘►4- Install or Connect (Figures 4, 5, and 17) installation of the commutator end frame. To
prevent such damage, install the O-ring seal as
described in the following steps.
NOTICE: For step s 1, 7, 8, and 9, refer to
A. Install the O-ring seal on the frame, field,
“NOTICE" on page 6D2B-1.
and brush holder group so that it is against
the shoulder on the field frame that will abut
the commutator end frame when installed.
This is the normal installed position of the
O-ring seal.
B. Carefully roll the O-ring seal out of its nor
mal installed position up onto the major out
er diameter of the field frame. Allow the seal
to remain in this position until the commuta
tor end frame is partially installed.
6. Commutator end frame.
A. Align the marks on the commutator end frame
and frame and field assembly made prior to
disassembly (figure 17).
B. Start the commutator end frame onto the frame
and field assembly, leaving a gap just slightly
larger than the thickness of the O-ring seal.
7. Brush plate screws.
• Use a scribe or similar tool to align the tapped
holes in the brush holder assembly with the
screw holes in the commutator end frame (fig
ure 5).
6D2B-12 28-M T STARTER MOTORS
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
removed. If a fastener needs to be replaced, u se the correct part num ber fastener for that application. If
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
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.
Figure 3— Connections for Generator Output Test

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.
3. Nut and washer from the shaft.

4. Pully, collar, fan, and outside collar from the shaft.
5. Drive end frame and the inside collar from the rotor
shaft.
6. Three screws and the retainer from the drive end
frame (figure 7).
• Press the bearing from the drive end frame.
7. Slip ring end bearing (if equipped) from the rotor
shaft using J 28509-A (figure 6).
• Some models have a pressed on race that
should not be removed.
SLIP RING END FRAME

Remove or Disconnect (Figures 4, 5, 8 and 9)
1. Three rectifier bridge to stator nuts.

2. Stator.
3. One screw from the brush holder and two insulated
screws from the regulator connector.
4. Brush holder, regulator, and connector from the
Figure 4—CS-144 Components end frame (figure 8).
Figure 5—CS-144 Components Figure 6— Removing the Slip Ring End Bearing
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.
Figure 9—Rectifier Bridge in End Frame
INSPECTION AND REPAIR

CLEANING AND INSPECTION |iy | Clean
• Brush holder. Make sure the brush pockets are

jjjj Clean clean.
• Brushes with a soft dry cloth.
• All metal parts except the voltage regulator, rectifier 2. Brushes for wear. If the brushes are worn to 11 mm
bridge, stator, rotor, and bearing assemblies in a (0.4 inch) or less in length, replace the brush hold
suitable solvent. er assembly. Use a retainer pin to hold the brushes
in the holders.
— Wipe or blow the parts dry. 3. Brush springs for broken wire or corrosion.
4. Slip ring end of the rotor shaft for overheating or
Inspect scoring. If signs of overheating or scoring are pre
sent, replace the rotor. The slip ring end bearing
must be replaced any time the two halves of the
1. Brush holder for damage.
generator are separated.
D. Finish with 400 grain or finer polishing cloth.

Blow away all dust.
10. Rotor and stator windings electrically as described
under “Electrical Tests”.
11. Generator housing for cracks, warping, or other
damage.
12. If the regulator, brush assembly, or connector
needs replacing, it will have to be unsoldered from
the other two components. Use as little heat as
possible to protect the regulator (figure 10).
ELECTRICAL TESTS
Except as stated, make the following tests with an
ohmmeter on the low range scale.
ROTOR FIELD WINDING TESTS

The rotor may be tested electrically with a self-pow-
ered test lamp or an ohmmeter (figure 11).
Open Winding Test

To test for opens, connect the test lamp or ohmmeter
to each slip ring. If the lamp fails to light, or if the
5. Drive end bearing for roughness, looseness, or ohmmeter reading is high (infinite), the winding is open.
wear. If the condition of the bearing is in doubt, Replace the rotor.
replace it.
6. Windings for burned insulation. Replace the rotor Grounded Winding Test
or stator if either looks burned. Connect a test lamp or ohmmeter from one slip ring
to the shaft. If the lamp lights, or if the reading is low,
• Burned insulation appears as very dark or
the rotor winding is grounded. Replace the rotor.
blackened wiring. A strong acidic odor will be
apparent. Short Circuit or Resistance Test
7. Terminal connectors for corrosion or breaks. Test the winding for short circuits or excessive resis
8. Windings on the stator for chipped insulation. If the tance by connecting a battery and ammeter in series
chipped area is small and the rest of the stator is with the edge of the two slip rings. Note the ammeter
OK, repair the stator with insulating varnish. reading and refer to “Specifications” later in this sec
9. Slip rings for scoring, wear, or pitting. tion. An ammeter reading above the specified value
indicates shorted windings.
A. If the rings are dirty, clean with a 400 grain or An alternate method is to check the resistance of the
finer polishing cloth. field by connecting an ohmmeter to the two slip rings. If
B. Spin the rotor and hold the polishing cloth the resistance reading is above the specified value, the
against the slip rings until they are clean. winding has excessive resistance; if below the specified
C. If scored, worn, or pitted, true the rings in a value, the winding is shorted. The specified resistance
lathe to 0.05 mm (0.002 inch). value can be determined by dividing the voltage by the
current.
Remember that the winding resistance and ammeter
readings will vary slightly with winding temperature. If
the rotor is not defective, but the generator fails to sup
ply rated output, the problem is in the rectifier bridge,
stator, or regulator.
If the rotor fails any of the above checks, replace it.
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.
RECTIFIER BRIDGE TEST

To test the rectifier bridge, connect an ohmmeter to
the grounded heat sink and one of the three terminals,
Figure 11—Testing the Rotor Field Windings pressing down firmly on the flat metal clip (figure 13).
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)
1. Terminal insulator to the outside of the slip ring end

frame.
2. BAT terminal to the rectifier bridge with a washer
and nut.
3. Rectifier bridge into the end frame.
4. Capacitor.
• Make sure the side with the insulator material is
placed against the end frame (ground).
5. Two bolts through the recifier bridge.
6. Two insulated screws through the rectifier bridge.
• If the brush holder, regulator, or connector has
been replaced, connect it by crimping the connec
tors) to the other component(s). Solder the con
nection using as little heat as possible to avoid
heat damage to the regulator (figure 10).
7. Brushes into the brush holder
A. If the brushes are being reused, be sure they
Figure 14— Stator Installed in the Slip Ring End are clean. Wipe them with a clean dry cloth.
Frame B. Retract the brushes in the holder.
2. Retainer with three screws.
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
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.
This d o es n o t apply to roller-type slip ring
en d frame bearings.
3. New slip ring end bearing onto the rotor shaft or

into the drive end housing (figure 15).
• Press against the inner race (bearings on the
rotor shaft) or the outer race (bearings in the
drive end housing) until the stop is reached.
4. Rotor shaft through the inside collar and through
Figure 15—Installing the Slip Ring End Bearing the end frame.
5. Outside collar, fan, and fan collar, onto the shaft
C. Retain the retracted brushes with a retaining (figure 6).
pin. 6. Pulley, washer, and pulley nut onto the shaft.
D. Make sure the pin extends through the end
frame when the brush holder is in place. After
NOTICE: Refer to “NOTICE" on page 6D3A-1.
the rotor and drive end frame are installed, the
pin will be pulled out, allowing the brushes to
contact the slip rings. Tighten
&
8. Brush holder, regulator and connector assembly
into the end frame (figure 8). • Pulley nut to 100 N-m (75 lbs. ft.).
• The metal side of the capacitor strap should

rest against the regulator connection.
MAIN ASSEMBLY
9. One bolt into the brush holder. * Assemble
• If a brush holder with locator bosses is being
replaced with a holder without locators, make 1. Drive end frame and rotor assembly to the slip ring
sure to align the brush holder assembly and end frame, lining up the marks.
hold it with your fingers while tightening the • If the slip ring end bearing is on the rotor shaft,
brush holder attaching screw. follow these steps:
10. Two insulated screws through the regulator con A. Carefully guide the slip ring end bearing into the
nector. slip ring end frame.
11. Stator into the end frame, aligning the three stator B. Make sure the tolerance rings on the bearing
leads to the three rectifier bridge terminals (figure outer race are not damaged.
14).
12. Three rectifier bridge nuts. Tighten the nuts secure 2. Four through-bolts. Tighten securely.
ly. A. Remove the brush retainer from the end frame.
B. Test the generator output.
DRIVE END FRAME
Install or Connect (Figures 4, 5, 6, and 15)
1. Drive end bearing into the frame (figure 6).

• Press against the outer race to press the bear
ing into place.
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

N-m Lbs. Ft.
Pulley Nut.................................................................................................. 100 74
T2532
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
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.
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
POLE PIECE AND COIL ASSEMBLY

The pole piece and plate assembly (often referred to
as the pickup coil assembly) consists of a stationary
pole piece with internal teeth and a pickup coil and
magnet that are located between the pole piece and a
bottom plate (figures 2 and 3).
DISASSEMBLY
1. Screws and washers holding the cap to the housing.

2. Cap from the housing.
3. Rotor from the shaft by lifting straight up.
4. Roll pin from the shaft.
A. Mark the shaft and driven gear with paint or
grease pencil for reassembly. The gear could
be installed 180 degrees off. Make sure the
gear is installed in the same position as
removed.
B. Drive out the roll pin with a small punch (figure Figure 2— 4.3L Engine Distributor Components
4).
5. Driven gear, washer, and tang washer.
6. Shaft with the pole piece and plate from the hous
ing.
• If the shaft can’t be removed from the distribu
tor housing due to varnish buildup, follow these
steps:
A. Secure the distributor housing in a vise with the
drive gear end DOWN and the pickup coil end
UP.
B. Using a cloth dampened with varnish remover,
clean the drive gear end of the shaft. DO NOT
allow varnish remover to travel up the driveshaft
to the grease pack in the top of the housing.
NOTICE: Failure to kee p cleaning a g en ts

away from the grease pack will result in pre
mature distributor failure.
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
1. Cap for cracks or tiny holes. Replace the cap if it is

worn, or damaged.
2. Metal terminals in the cap for corrosion. Scrape
them clean with a knife or replace the cap.
3. Rotor for wear or burning at the outer terminal. The
presence of carbon on the terminal indicates rotor
wear and the need for replacement.
4. Shaft for shaft-to-bushing looseness. Insert the
shaft in the housing. If the shaft wobbles, replace
the housing and/or shaft.
5.Housing for cracks or damage. Figure 4— Removing/Installing the Roll Pin
DISTRIBUTORS 6D4A-3
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)
NOTICE: Thoroughly coat the bottom o f the

ignition control m odule with P/N 1974984 sili
cone dielectric grease. Failure to do so could
result in premature failure o f the module.
• Lubricate the bottom of the ignition control module
and the module rest pad in the housing with P/N
1974984 silicone dielectric grease or an equivalent
heat transfer substance.
1. Ignition control module to the housing with two
screws. 7. Tang washer, washer, and driven gear onto the
2. Pickup coil. bottom of the shaft.
• Fit the tab on the bottom of the coil into the • Align the marks on the driven gear, housing,
anchor hole in the housing. and shaft assembly.
3. Pickup coil wiring connector to the module. 8. Roll pin into the gear.
• Make sure the locking tab is in place. • Spin the shaft and make sure the teeth on the
4. Shield onto the coil. shaft assembly do not touch the pole piece.
5. Lubricate the lower housing bushing with a few 9. Rotor onto the shaft.
drops of engine oil. • Fit the tab in the rotor into the shot on the shaft.
6. Shaft assembly into the housing. 10. Cap to the housing with screws and washers.
6D4A-4 DISTRIBUTORS
SPECIAL TOOLS
1. MODULE TESTER
2906r5021
HIGH VOLTAGE SWITCH 6D4B1-1
SECTION 6D4B1
HIGH VOLTAGE SWITCH

result in possible air bag deployment, personal injury or otherwise unneeded SIR system repairs.
NOTICE: When fasteners are removed, always reinstall them at the sa m e location from which they were
be used. Fasteners that are not reused and those requiring thread locking com pound will be called out.
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).
IGNITION COIL/COIL DRIVER

The coil driver controls the interface between the igni
tion coil and the VCM. The interconnects are made by
the primary engine harness. The ignition coil can gener
ate up to 35,000 volts and connects to the HVS through
a secondary wire.
6D4B1-2 HIGH VOLTAGE SWITCH
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.
CAMSHAFT POSITION SENSOR

The camshaft position sensor connectes to the
VCM-A through the primary engine harness and pro
vides cylinder identification. The camshaft position sen
sor is internal to the High Voltage Switch (HVS).
CRANKSHAFT POSITION SENSOR
The crankshaft position sensor is a digital sensor that
provides reference information to the VCM-A for spark
and fuel delivery. The crankshaft position sensor is
located in the front timing chain cover.
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.
4- + Remove or Disconnect (Figures 2, 3, and 4)
1. Two screws holding the cap to the housing.

2. Cap from the housing.
3. Two screws from the rotor
4. Rotor.
• Note which holes the screws were removed
from (figure 3).
5. Two screws holding the camshaft position sensor.
6. Camshaft position sensor.
• Line up the square cut-out and the camshaft
position sensor before removing (figure 3).
Figure 4— Removing/Installing the Roll Pin
7. Roll pin from the shaft.

A. Mark the shaft and driven gear with paint or a
grease pencil to aid reassembly. Do not scribe
or scratch a line in the gear. It could affect the
camshaft position sensor. The gear could be
installed 180 degrees off. Make sure the gear is
installed in the same position as removed.
B. Drive out the roll pin with a punch (figure 4).
8. Driven gear, washer, and tang washer.
9. Shaft.
• If the shaft can’t be removed from the high volt
age switch housing due to varnish buildup, use
a cloth dampened with varnish remover to clean
the shaft.
_
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
1. Cap for cracks or tiny holes. Replace the cap if it is

worn or damaged.
2. Metal terminals in the cap for corrosion. Scrape
them clean with a knife or replace the cap.
3. Rotor for wear or burning at the outer terminal. The
presence of carbon on the terminal indicates rotor
wear and the need for replacement.
4. Shaft for shaft-to-bushing looseness. Insert the
shaft in the housing. If the shaft wobbles, replace
the housing and/or shaft.
5. Housing for cracks or damage.
• Refer to the Driveability, Emissions and Electri
cal Diagnosis manual for ignition system diag
nosis.
IGNITION COIL TEST Figure 6—HVS Alignment Indicators
Measure
• Resistance of the ignition coil with an ohmmeter.

A. Connect the ohmmeter as shown in figure 5,
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, 3, 4, 6, 7, and 8)
1. Camshaft position sensor.

2. Two screws holding the camshaft position sensor.
3. Shaft.
Figure 7— Rotor Alignment Position
4. Tang washer, washer, and driven gear.

• When properly installed, the roll pin, predrilled
indent hole in gear, and arrow on housing
should be in-line. Install the high voltage switch
in this position (figure 6).
5. Roll pin.
6. Rotor (figure 3).
• “A” shows the mounting holes. “B” shows the
locating holes.
• The electrical tab on the rotor should be in line
with the cap hold down tab nearest the arrow
on the shaft (flat side of housing)(figure 7).
When the housing is installed, the rotor electri
cal tab will point to the indent marked with a 6
on the top side of the housing (figure 8).
7. Two screws holding rotor.
8. High voltage switch cap.
9. Cap to the housing with two screws.
6D4B1-4 HIGH VOLTAGE SWITCH
Figure 8—Rotor Final Position

TRANSMISSION 7-1
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
Borg-Warner 4401 Transfer Case............................................................................................................................ 7D4-1
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
TRANSMISSION DISASSEMBLY 2-4 Servo Assembly

General Service Information Figures 2 and 3
Figure 1 Tool Required:

J 29714 Servo Cover Com pressor
Tool Required:
J 8763-02 Holding Fixture and Base E Remove or Disconnect
1. Install J 29714.
NOTICE: It is not recom m ended to use air
p o w e re d to o ls to d isa s s e m b le o r asse m b le 2. Servo cover retaining ring (29).
transm issions/transaxles. Im proper bolt torques 3. Servo cover and O -ring seal (28 and 27).
can contribute to transm ission repair conditions • If the servo cover seem s to be hung up on
and this inform ation, vital to diagnosis, can only the seal, cut and rem ove the O-ring seal
be detected when using hand tools. before rem oving the cover.
• Teflon Oil Seal Rings 4. 2-4 servo assem bly (12-26).
If any seal rings are dam aged, cut, or do not
rotate freely in their groove be certain to check
the ring groove for debris, burrs, or damage.
• Thrust W asher Surfaces J 29714
The thrust washer and thrust bearing surfaces
may appear to be polished. This is a normal
condition and should not be considered damage.
|ig | Clean
• T horoughly clean the exterior o f the trans

m ission.
□ Remove or Disconnect
• Torque Converter (1).
Install or Connect
1. J 8763-02 onto the transm ission case.

2. H olding fixture into the base.
E Remove or Disconnect
• Drain the transm ission fluid out case extension
by rotating transm ission so bell housing is up.
8763-02 20 HOUSING, SERVO PISTON

(INNER)
12 SPRING, SERVO RETURN 21 SEAL, O-RING
13 PIN, 2ND APPLY PISTON 22 SPRING, SERVO APPLY PIN
14 RING, RETAINER (2ND 23 WASHER, SERVO APPLY
APPLY PISTON) PIN
15 RETAINER, SERVO 24 RING, RETAINER (APPLY
CUSHION SPRING PIN)
16 SPRING, SERVO CUSHION 25 PISTON, 4TH APPLY
17 PISTON, 2ND APPLY 28 COVER, 2-4 SERVO
18 RING, OIL SEAL (2ND 29 RING, SERVO COVER
APPLY PISTON - OUTER) RETAINING
19 RING, OIL SEAL (2ND
APPLY PISTON - INNER) R H 0101-4L60-E
SH 0100-4L60-E
Figure 2 Servo Cover Removal

Figure 1 Holding Fixture
Servo Pin Length

Figures 3, 4 and 5
Tools Required:
J 33037 B and Apply Pin Tool
J 22269-01 Piston Com pressor
As a diagnostic aid, the servo pin length should
now be checked. If the pin length is too short or too
long, be certain to inspect the 2-4 band and reverse
input drum for damage or w ear when disassem bled.
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
Figure 3 Servo Pin Length

|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).
14 RING, RETAINER (2ND APPLY PISTON)

17 SECOND APPLY PISTON RH0103-4L60-E
Figure 4 Second Servo Piston Retaining Ring Removal
ILL.
NO. DESCRIPTION
12 SPRING, SERVO RETURN
13 PIN, 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
Figure 5 Servo Assem bly

Speed Sensor and Case Extension

Figures 6 and 7
Tool Required:
J 38417 Speed Sensor Rem over and
Installer
1. Speed sensor retaining bolt (35).

2. Speed sensor assem bly (36) and O-ring seal
(37) with J 38417.
3. Case extension bolts (32), case extension (31)
and extension seal ring (30).
4. O utput shaft sleeve (690) and output shaft
O-ring seal (691).
• N ot all models use an output shaft sleeve
ILL.
and seal. NO. DESCRIPTION
8 CASE, TRANSMISSION
30 SEAL, CASE EXTENSION TO CASE
31 EXTENSION, CASE
32 BOLT, CASE EXTENSION TO CASE
33 BUSHING, CASE EXTENSION
34 SEAL ASSEMBLY, CASE EXTENSION OIL
35 BOLT, SPEED SENSOR RETAINING
36 SPEED SENSOR, INTERNAL TRANSMISSION
37 SEAL, O-RING (ITSS TO CASE EXTENSION)
687 SHAFT, OUTPUT
RH0106-4L60-E
J 38417
Figure 7 Extension and Associated Parts

35 BOLT, SPEED SENSOR RETAINING
36 SPEED SENSOR, INTERNAL
SH0105-4L60-E
TRANSMISSION
Figure 6 Speed Sensor Removal

Pan And Filter Assembly

F ig u re 8
[g | Clean
• Exposed ends o f bottom pan screws and spray
w ith penetrating oil.
|<--»| Remove or Disconnect

1. Screws (76), oil pan (75) and gasket (73).
2. Oil filter (72) and filter seal (71).
• Filter seal may be stuck in the pump.
|y | Inspect
• Filter (72), open filter by prying the metal
crim ping away from the top o f the filter
(black) and pull apart. The filte r m ay
contain evidence for root cause diagnosis.
- Clutch material.
- Bronze slivers indicating bushing wear.
- Steel particles. 71 SEAL, FILTER
72 FILTER ASSEMBLY, TRANSMISSION OIL
73 GASKET, TRANSMISSION OIL PAN
Valve Body And Wiring Harness 75 PAN, TRANSMISSION OIL
F ig u re s 9 th r o u g h 14 76 SCREW, TRANSMISSION OIL PAN S H 0107-4L60-E
Remove or Disconnect Figure 8 Pan, F ilter and Seal R em oval
F ig u re s 9 a n d 10
1. Electrical connections from components.

2. TCC PW M Solenoid Retainer Clip (379) and
Solenoid (396).
3. TCC Solenoid bolts (68) and solenoid assem bly
(66) with O-ring seal (65) and wiring harness.
4. Pressure switch assembly bolts (70) and pressure
switch assem bly (69).
5. A ccum ulator cover bolts (58 and 59) and 1-2
accum ulator cover and pin assem bly (57).
6. 1-2 accum ulator piston (56) and seal (55).
7. Spring (54).
8. Dipstick stop bracket (93).
58 BOLT, ACCUMULATOR COVER

62 BOLT, VALVE BODY
64 BOLT, MANUAL DETENT SPRING
68 BOLT, HEX WASHER HEAD (SOLENOID)
70 BOLT, PRESSURE SWITCH ASSEMBLY
93 BRACKET, DIPSTICK STOP
364 BOLT, FORWARD ACCUMULATOR COVER
379 RETAINER, SOLENOID
396 TCC PWM SOLENOID
S H 0108-4L60-E
Figure 9 Valve Body Bolt Locations

63 SPRING ASSEMBLY, MANUAL DETENT

88 LEVER, INSIDE DETENT
89 LINK, MANUAL VALVE
340 VALVE, MANUAL
Figure 11 Manual Valve Link
60 VALVE ASSEMBLY, CONTROL BODY

62 BOLT, VALVE BODY
64 BOLT, MANUAL DETENT SPRING
66 SOLENOID ASSEMBLY, WIRING HARNESS AND
69 SWITCH ASSEMBLY, TRANSMISSION PRESSURE
70 BOLT, PRESSURE SWITCH ASSEMBLY
93 BRACKET, DIPSTICK STOP SH0109-4L60-E
Figure 10 Control Valve and Pressure Switch Assembly
|<—►
[ Remove or Disconnect
Figures 9,11 and 12

1. Bolt (64) and m anual detent spring assem bly
(63).
2. W iring harness retaining bolts.
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
Figure 12 Accum ulator Assembly, Spacer Plate

and Gaskets
#8 #4
2 3RD ACCUMULATOR 38 PLUG, TRANSMISSION CASE (ACCUM. BLEED)

3 REVERSE INPUT 40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM.
4 3-4 CLUTCH EXHAUST 91 NO. 1 CHECKBALL
5 OVERRUN CLUTCH FEED 92 SCREEN,TCC
6 OVERRUN CLUTCH CONTROL
8 1-2 UPSHIFT
12 FORWARD CLUTCH ACCUM. RH0112-4L60-E R H0113-4L60-E-R1
Figure 13 Valve Body Checkballs Figure 14 Case Checkballs and Filters

Transmission End Play Check

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
1. Rem ove an oil pum p bolt (2) and install a 278

m m (11 inch) bolt and locknut or J 25025-7A.
Oil Pump Assembly
2. Install J 25022-A or J 34725 as shown.
3.
Install J 24773-A as shown. Tools Required:
4. Install dial indicator. J 37789-A Oil Pum p Rem over and Installer
A. Set to zero. J 39119 A dapter
B. Pull up on J 24773-A.
C. End play should be 0.13 to 0.92 mm (0.005 □
to 0.036 inch). 1. O-ring seal (618).
2. All oil pum p bolts (2) and O-rings (3).
3. Slide J 39119 over stator shaft until it locks
under splines.
4. Oil pum p assem bly (4) with J 37789-A.
5. Oil pum p to case seal (5) and gasket (6).
6. Reverse input clutch to oil pum p thrust w asher
A 298mm TURBINE SHAFT

B 245mm TURBINE SHAFT
RH0114-4L60-E Figure 17 Oil Pump Removal
Figure 15 End Play Tool

2-4 Band, Reverse Input Clutch, Input Clutch

And Input Gear Set
Tools Required:
J 29837 O utput Shaft Support Fixture
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
• O utput shaft (687) m ay fall free w hen

retaining ring (661) is rem oved if J 29837
is not used.
J 29837
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
3. J 29837 and output shaft (687). Reaction Gear Set

[T| Important Figure 21
• The m anufacturer assem bles the output |<--»| Remove or Disconnect
sh a ft and re a c tio n in te rn al g e a r w ith
adhesive for ease o f assembly. If these parts 1. Input internal gear (664) and reaction carrier
have not becom e separated during use, the ( 666).
output shaft will come out later along with 2. Reaction sun shell (670) and thrust w asher
the reaction internal gear. (669).
4. Thrust bearing assem bly (663). 3. Reaction sun shell to inner race thrust w asher
(674).
4. Lo and reverse support to case retainer ring
(676).
5. Lo and reverse clutch support retainer spring
(680).
6. Reaction sun gear (673).
7. Lo and reverse inner race (675), roller assem bly
(678), support assem bly (679) and reaction
carrier assem bly (681).
8. Lo and reverse clutch plates (682).
9. Reaction internal gear (684) and thrust bearing
assem bly (683).
10. Reaction gear support to case bearing (692).
661 RET, OUTPUT SHAFT TO INPUT CARRIER
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
REACTION SHAFT)
RH0119-4L60-E
Figure 20 Input C arrier R em oval

Lo And Reverse Clutch Parts

F ig u re s 2 2 , 2 3 a n d 2 5
Tools Required:
J 34627 Snap Ring R em over/Installer
J 23327 Clutch Spring C om pressor
|<—»| Remove or Disconnect
1. Bolts (715) and parking lock bracket (710).
[~f~| Important
• D ue to interference, the parking pawl may

have to be rem oved before rem oving or
installing the low and reverse piston.
A. Parking pawl shaft plug (78) w ith a #4
screw extractor.
B. Parking pawl pivot shaft (79) with a
magnet.
C. Parking pawl (81) and return spring
(80).
2. Install tool J 23327.
3. Lo and reverse clutch retainer ring (693) with
J 34627.
4. Lo and reverse clutch spring assem bly (694).
5. Lo and reverse clutch piston (695).
• A p p ly a ir p re ssu re in the c a se ap p ly
passage.
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
Figure 21 Reaction Gear Set Removal

A
A APPLY AIR PRESSURE HERE TO REMOVE LO AND
REVERSE PISTON FROM THE CASE
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
|<-»| 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
• M anual shaft seal (82).
- Pry out with a screwdriver.
|-><-| Install or Connect
• New m anual shaft seal (82).

- Tap into place using a 14 mm socket.
82
A
84.
82 SEAL, MANUAL SHAFT
84 SHAFT, MANUAL RH0124-4L60-E
Figure 25 Manual Shaft Seal
J^l Inspect Case

F ig u re 2 4
F ig u re s 2 6 , 2 7 a n d 2 8
A ctuator rod (85) for damage.
1^1 Inspect
Inside detent lever (88) for dam age or cracks.
M anual shaft (84) for dam age or burrs. Case (8) exterior for cracks or porosity.
M anual detent spring assem bly (63) for roller C a se to v a lv e b o d y fa c e f o r d a m a g e ,
freeness or damage. interconnected oil passages and flatness.
Install or Connect - Face flatness can be checked by inspecting
B the spacer plate to case gasket for proper
F ig u re 2 4
land im pressions.
• Parking lock actuator (85) onto inside detent Vent assem bly (9) for damage.
lever (88).
A ir check all oil passages.
• M anual shaft (84) into case (8) and inside detent
lever (88). - See d iag n o sis se ctio n fo r oil p a ssa g e
identification.
• Inside manual shaft nut (90) onto m anual shaft
(84). 2-4 servo bore for:
Tighten - Dam age, porosity, or burrs.
a
- Any sharp edges (i.e. - oil passages, slots
• Nut (90) to 31 N*m (23 lb. ft.) for retaining ring rem oval - rem ove if
• M anual shaft retainer (83) onto manual shaft found).
(84).
O rifice cup plug (11) in servo bore for debris or
COMPONENT REPAIR AND damage.
TRANSMISSION REASSEMBLY Third accum ulator bore for:

- Porosity, dam age, or burrs.
The assem bly of some com ponents will require
use of an assem bly lube. It is recom m ended that - Pin dam age (43).
Transjel™ J 36850 or equivalent be used during - Orifice cup plug (42) dam aged or plugged.
assembly. Speed sensor bore for:
NOTICE: Do not use any type o f grease to retain - Dam age.
parts during assem bly of this unit. Greases other
- Sharp edges.
than the recom m ended assem bly lube will change
tra n sm issio n flu id c h a ra c te ristic s and cause - Porosity.
undesirable shift conditions and/or filter clogging. All bolt holes for thread damage
Case Assembly - Heli-coil to repair.
Cooler connectors (10) for:
Clean
- Dam age.
Thoroughly with solvent.
- Proper torque 38 N»m (28 lb. ft.).
Air dry.
- Do not wipe with cloth.
• Case interior for: Third Accumulator Retainer and Ball Assembly

- Dam aged ring grooves or casting flash. Figure 29
- Clutch plate lugs worn or damaged.
[y | Inspect
- Bushing (33) scored, worn, or damaged (see
Bushing Replacem ent). • Ball for:
- Presence.
- Sticking or leaking.
• Retainer for:
- Presence.
- Loose.
- Incorrect seating.
- Restricted feed slots.
Retainer and Ball Assembly Leak Check

Procedure
Figure 29
1. Install the servo assem bly (12-26) into the servo
bore.
2. Install the servo cover (28) and retainer (29).
3. Pour a suitable solvent into the accum ulator
bore.
11^1 Inspect
• W atch for leakage inside the case.

A 2-4 SERVO BORE • If le a k a g e is o b se rv e d , re p la c e th e th ird
B SERVO EXHAUST HOLE accum ulator retainer and ball assembly.
C 2ND 7 4TH BAND APPLY PASSAGE
D 3RD ACCUM. PRESSURE TAP PASSAGE
11 PLUG, CASE SERVO Replacement Procedure - Third Accumulator
40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM. Retainer and Ball Assembly
RH0061-4L60-E Figures 29 and 30
Figure 27 2-4 Servo Bore Tools Required:
6.3 m m (#4) Screw Extractor
9.5 m m (3/8 inch) diam eter m etal rod
• Third accum ulator retainer and ball assem bly

(40).
- Use 6.3 mm (#4) screw extractor.
0 Install or Connect
Figures 29 and 30
A 3-4 ACCUMULATOR BORE
38 PLUG, TRANSMISSION CASE • A new third accum ulator retain er and ball
(ACCUM. BLEED) RH0126-4L60-E assembly.
- Oil feed slots in the retainer m ust line up
Figure 28 Third Accum ulator Bore
with oil passage in the servo bore. To be
certain of correct installation depth, scribe
a m ark at 42.0 m m (1.653 inch) on the 9.5
m m (3/8 inch) diam eter m etal rod. Use it
to seat the third accu m u lato r and ball
assem bly as shown. W hen the scribed line
is flush with the case face, installation depth
is correct.
B Install or Connect
F ig u re 3 2
1. Piston seals (696) onto the piston (695).

• L u b ric a te w ith T ran sjel™ J 3 6850 or
equivalent.
2. Piston (695) into the case:
• Index the piston w ith the notch in the
bottom of the case.
3. Spring assem bly (694) onto the piston.
• Flat side o f the retainer upward.
A 3RD ACCUMULATOR BORE 4. J 23327 over the spring assembly.
C CASE INTERIOR • Com press the spring assembly past the ring
D 2-4 SERVO BORE groove in the case hub.
40 RETAINER & BALL ASSEMBLY, 3RD ACCUM.
R H0127-4L60-E 5. Retainer ring (693) into the case hub ring groove
with J 34627.
Figure 29 Leak Check - 3rd Accumulator
I 693
DRIVE UNTIL SCRIBE MARK

IS FLUSH WITH CASE RH0128-4L60-E
Figure 30 Third Accumulator Retainer and Ball Asm. -

Installation
Lo and Reverse Clutch Piston

F ig u re s 3 1 a n d 3 2
Tools Required:
J 34627 Snap Ring R em over/Installer 8 CASE, TRANSMISSION
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.
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
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.
Reaction Internal Gear and Carrier Assembly

Figures 34,35 and 36
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.
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.
• 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.
A PINION GEAR END PLAY -

.20mm/.60mm (.0087.024")
RH0131-4L60-E
Figure 34 Pinion End Play Check
681 683 685 692
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER./
SUPPORT)
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
Figure 36 Reaction Internal Gear and Carrier Bearing

Figure 35 Captive Thrust Bearing Check
Locations
Reaction Internal Gear and Support

Lo and Reverse Clutch Spacer Plate Selection
F ig u re 4 1
F ig u re s 3 7 th r o u g h 4 0
B Install or Connect Tools Required:
1. Reaction gear support to case bearing (692) onto Scale
the case hub as shown. Straight edge
• Outside bearing race goes toward case hub.
682C
682D
INSTALL THE APPROPRIATE SELECTIVE

SPACER PLATE TO THE FINAL
ASSEMBLY AFTER DIMENSION "D"
IS OBTAINED. IDENTIFICATION SIDE UP.
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
Figure 37 Measuring For Spacer Plate Selection
1 Measure 3. M easure the height o f the clutch pack from the

work surface to the top o f the lo and reverse
Figures 37,38 and 39 clutch support (dim ension D).
1. To m easure for proper selective spacer plate, 4. Use dim ension D to select the proper thickness
stack the lo and reverse assem bly on a flat of the selective spacer plate for assembly.
surface in the following order: 5. Install the proper selective spacer plate betw een
A. One waved plate (682B). the wave plate and the first com position clutch
B. F ive com position and four steel plates plate with the identification side up.
(682), starting with one com position plate 6. The overall height for dim ension D with the
and alternating with steel. selective spacer plate included should be 29.22
C. Lo and reverse clutch support (679). to 29.90 m m (1.20 to 1.24 inch).
2. Apply an evenly distributed load to the top o f
the lo and reverse support assembly (679). Light LO AND REVERSE CLUTCH
pressure (approxim ately 22 N or 5 lbs.) on the
QTY. THICKNESS
lo and reverse support assem bly (679) will
provide the correct dim ension for m easurem ent. PLATE - WAVED 1
2.42mm
(.096")
NOTICE: Excessive pressure will start to flatten PLATE - SELECTIVE 1
the w a v e p la te re s u ltin g in an in a c c u ra te SEE FIG. 39
m easurem ent. PLATE - COMP. FACED
2.25mm
5
(.088")
1.75mm
i L / \ 1l r L A I o 1fc t L o
(.069”)
R H0135-4L60-E
Figure 38 Lo and Reverse Clutch Plate Chart

LO AND REVERSE CLUTCH SPACER PLATE SELECTION CHART
IF GAGE DIMENSION “ D " IS USE THIS SELECTIVE PLATE
FROM TO IDENTIFICATION PLATE THICKNESS
28.065mm 27.545mm 1.684mm 1.829mm

NONE
(1.102") (1.081") (.066") (.072")
28.586mm 28.066mm 1.314mm 1.168mm

0
(1.122") (1.102") (.052") (.046")
27.544mm 27.026mm 2.198mm 2.344mm

1
(1.081") (1.061") (.087") (.092")
R H0136-4L60-E
Figure 39 Lo and Reverse Spacer Plate Selection Chart

1. W aved plate (682A).

2. C orrect selective spacer plate (682B), from
selection procedure.
3. Lo and reverse clutch plates (682) into case
lugs.
• Start with a com position plate and alternate
with steel.
• Index with the splines of the reaction carrier
and the case as shown.
682 PLATE ASSEMBLY,
LO AND REVERSE CLUTCH
682 PLATE ASSEMBLY, LO AND REVERSE CLUTCH
682A PLATE, LO AND REVERSE CLUTCH (WAVED)
682B PLATE, SPACER LO AND REVERSE CLUTCH
(SELECTIVE)
RH0137-4L60-E SUPPORT)
684 GEAR, INTERNAL REACTION
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
Figure 41 Reaction Internal Gear and Carrier Assem bly

Installation
Lo and Reverse Clutch Support Assembly • Support assem bly for:

- Cracks or dam aged lugs.
|<—>| Remove or Disconnect E3 Install or Connect

Figure 42 Figures 42,43 and 44
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.
ALIGN WIDE NOTCH

WITH WIDE CASE LUG.
S H 0140-4L60-E
Figure 43 Lo and Reverse Support and Roller Asm.

Installation
A LOCKED UP
B FREEWHEELS
677 RING, LO AND REVERSE RETAINER (ROLLER
ASSEMBLY/CAM)
679 SUPPORT ASM., LO AND REVERSE CLUTCH
680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
SUPPORT RETAINER) RH0139-4L60-E
Figure 42 Lo and Reverse Clutch Support Assembly
[jy | Inspect
Figure 42
• Inner race (675) for dam age and surface finish. 8 CASE, TRANSMISSION
• 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.
Reaction Sun Gear and Shell

Figure 45
[y ] inspect
• Reaction sun gear (673) for:

- N icked, scored, or w orn bushing (See
Bushing Replacem ent).
- Dam aged spline or teeth.
- L oose or w eak reta in in g ring (do not
rem ove this ring, except to replace it.).
• Reaction sun shell (670) for:
- Stripped or worn splines.
- Broken hub.
- Bent tangs.
• Lo and reverse inner race to reaction sun gear
shell thrust washer (674) for wear or damage.
• Reaction shaft to reaction sun gear shell bronze
thrust w asher (669) for w ear or damage.
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
• Index the four locating ears into the inner
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.
• Input internal gear (664) for: B Install or Connect

- Cracks.
F ig u re 4 7
- Dam aged spline or gear teeth.
• Input carrier to reaction shaft thrust bearing 1. Place new rotor over output shaft.
(663) for w ear or damage. 2. Place J 36352-4 in groove on output shaft.
• O utput shaft (687) for: 3. Place J 36352-6 on shaft and press to m ake
- Plugged or restricted lube passages. contact with J 36352-4.
- D am aged splines or ring groove.
REMOVAL INSTALLATION
- Dam aged governor drive gear teeth.
- Burrs or dam age to the front of the shaft at J 8433
PRESS
seal area. (P olish w ith crocus cloth if
necessary).
- Burrs or damage to bearing journals. J 36352-4
664 666 668 J 36352-6
J 21427-01
699
687
687 SHAFT, OUTPUT

699 ROTOR, INTERNAL TRANSMISSION SPEED SENSOR
RH0144-4L60-E
664 GEAR, INPUT INTERNAL
666 SHAFT, REACTION CARRIER
668 RING, REACTION SHAFT/INTERNAL GEAR RETAINER Figure 47 Transmission Output Speed Sensor Rotor
RH0143-4L60-E
Figure 46 Input Internal Gear and Reaction Shaft Input Internal Gear and Output Shaft
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
• Install J 21427 with J 8433 and rem ove rotor.

Input Carrier and Sun Gear

Figure 50
Tool Required:
[jjfr] Inspect
• Input carrier assem bly (662) for:

- Pinion gear damage.
- Excessive pinion washer w ear - end play
should be 0.20 to 0.61 mm (0.008 to 0.024
inch).
- Proper pin stake.
- Keystoned pinion gears (pinion gears m ust
rotate freely).
- D am aged or w orn thrust bearing.
• To check the captive thrust bearing in
the carrier for wear, place a bushing or
an output shaft sleeve on the bearing
663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
race (do not contact the pinion gears)
REACTION SHAFT) and turn it w ith the palm of your hand.
664 GEAR, INPUT INTERNAL Any im perfections will be felt through
666 SHAFT, REACTION CARRIER the bushing.
668 RING, REACTION SHAFT/INTERNAL GEAR RETAINER
RH0145-4L60-E • Input sun gear (658) for:
- B ushing dam age or w ear (see B ushing
Figure 48 Input Internal Gear Installation R eplacem ent Procedure).
- Cracks.
- Dam aged spline or gear teeth.
|-»<-| Install or Connect
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.
3. The 3-4 clutch plates (654).

4. Five 3-4 clutch boost spring assem blies (600).
5. The 3-4 clutch apply plate (653).
6. The 3-4 clutch ring retainer plate (652).
7. Forward clutch backing plate retainer ring (651)
and backing plate (650).
8. Forward clutch sprag assem bly (638-648).
658 GEAR, INPUT SUN
661 RET., OUTPUT SHAFT TO INPUT CARRIER
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
RH0146-4L60-E
Figure 50 Input Carrier and Sun Gear - Installation
Input Clutch Assembly

Tools Required:
J 23456 Clutch Spring Com pressor Press
J 23327-1 Clutch Spring Com pressor
J 2 5 0 1 8-A C lu tc h S p rin g C o m p re sso r
Adaptor
|<$»| Disassemble
Figure 53
Figures 51 and 53
1. Input sun gear bearing assem bly (637).
• Reverse input clutch assem bly (605) from the
2. Input housing to output shaft lip seal (636).
input clutch assem bly (621).
3. Forw ard clutch plates (649).
• Oil pum p to selective w asher thrust bearing
(615). 4. Forward wave plate (648).
• Selective washer (616). 5. Forw ard clutch apply plate (646).
6. O verrun clutch plates (645).
|<y»| Disassemble
|fo | Disassemble
Figures 52 and 53
Figure 53
1. Place the input clutch assem bly (621) on the
bench with the turbine shaft through the bench 1. Install J 23456 and J 23327-1 with J 25018-A.
hole. • Com press overrun clutch spring assem bly
2. The 3-4 clutch plate retainer ring (656) and the (634).
backing plate (655). 2. O verrun clutch retainer ring (635).
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.
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
Figure 53 Input Clutch Assembly

|p | Inspect
• Turbine shaft O -ring seal (618) for:

- Damage.
- Nicks or cuts.
• Input housing check valve ball (620):
- The ball m ust m ove freely.
- Leak check the ball with solvent.
|~9~] Important
• If the 3-4 clutch plates are burned or w orn and

a cau se is not fo u n d during d iag n o sis or
disassembly, replacem ent of the retainer and
checkball assembly may be required (Figure 54).
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
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
Figure 56 V iew s o f th e Input H ousing

Figure 54 In p u t H ousing Check Valve Ball
F ig u re 5 7
• Tap out retainer and ball assembly.
p7| Install or Connect

• U sing sam e tools, tap in retain er and ball

assem bly until shoulder is seated in housing.
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
Figure 55 Retainer and Ball Assem bly - Replacement

1. Inner and outer 3-4 clutch lip seals (624) on the

3-4 clutch piston.
• Seal lips m ust face away from the piston
hub.
• Lubricate the seals with Transjel™ J 36850
or equivalent.
2. The 3-4 clutch piston (623) into the input
housing as shown.
• Use care not to dam age the seals.
Figure 58 Input Housing and 3-4 Piston
\jy \ Inspect
• Forward clutch housing (628) for:

- Proper checkball operation.
- Dam age or distortion.
Figure 57 Retainer and Checkball Removal/Installation
- Burrs in seal areas.
Inspect - Cracks.
• Forward clutch piston (630) and overrun clutch
F ig u re 5 3
piston (632) for:
• The 3-4 clutch piston (623) for dam age or - Porosity or damage.
porosity. - Ring groove damage.
• The 3-4 clutch apply ring (625) for: - Apply leg damage.
- Bent tangs.
• O verrun spring assem bly (634) for dam age or
• The 3-4 clu tch spring assem bly (626) for distortion.
dam age or distortion. • Input housing to output shaft lip seal (636) for
• The 3-4 clutch boost spring assem blies (600) dam age or wear.
for dam age or distortion.
|^ | Assemble
I5 l Assemble
F ig u re 5 8
1. Forward clutch housing to input clutch housing
Position the input housing and shaft assem bly O -ring seal (622) as shown.
on the bench with the turbine shaft through a bench • L u b ric a te w ith T ran sjel™ J 3 6850 or
hole. equivalent.
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.
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
,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.
equivalent.
3. Align the tangs on the two composition overrun
clutch plates.
* ALIGN WIDE NOTCHES TO CASE LUGS
OVERRUN CLUTCH
MODEL FLAT STEEL COMP. FACED
THICK THICK
NO. NO.
NESS NESS
ALL 2.248mm 2.400mm 2.03mm

MODELS (.089" .094") (.079")
Figure 62 Input Hsg. to O utput Shaft Lip Seal
RH0158-4L60-E
Figure 63 Overrun Clutch Plate Chart

• Forw ard sprag outer race (644) for:

- Spline damage.
- Surface finish damage.
- Plugged lubrication holes.
637 638 639 643 642 643 644 641

644 RACE, FORWARD CLUTCH (OUTER) RH0160-4L60-E
Figure 65 Forward Clutch Sprag Assembly

658 GEAR, INPUT SUN Assemble
RH0159-4L60-E
Figures 66, 67 and 68
Figure 64 In p u t Sun Gear T h ru st Bearing
1. Forw ard clutch sprag assem bly (642) into the
outer race.
Forward Clutch Sprag Assembly
• To correctly install, the notches in the sprag
F ig u re s 6 5 th r o u g h 71 cage m ust face upw ard as shown.
|<$»| Disassemble 2. One sprag retainer ring (643) onto the race and
retainer assembly.
F ig u re 6 5
• The flange on the retainer ring m ust face
1. Forward sprag outer race (644). away from the retainer.
2. Overrun clutch hub retaining snap ring (638) 3. R ace and retain er assem bly into the sprag
and clutch hub (639). assembly.
3. Forward clutch retainer and race assembly (641). A. To assem ble, hold the outer race in your
left hand with your fingers supporting the
Iffi Inspect sprag at the recessed side of the outer race.
• Forward clutch sprag assem bly (642) for: B. Insert the race and retainer assem bly by
- W ear or damage. pushing in and turning to the left.
- W eak or broken springs. 4. The rem aining retainer ring onto the sprag
- Dam aged or m issing retainer caps (brass). assembly.
• Overrun clutch hub (639) for: 5. Overrun clutch hub (639).
- Spline damage. 6. O verrun clutch hub retaining snap ring (638)
- Plugged lubrication holes. into the snap ring groove of the race and retainer
assembly.
- Dam aged tangs.
7. Test the assembly for proper operation as shown
- Cracks.
(Figure 68).
• Forward clutch retainer and race assembly (641)
for: |~ f] Important
- Spline damage.
• If the assem bly operates backw ards, you
have in sta lle d the sprag b a c k w a rd s
- Surface finish damage. Reassem ble correctly!'
- Loose retainer.
|-»fr-| Assemble
• Forward clutch sprag assem bly into the input

clutch housing.
- Index the overrun clu tch hub into the
overrun clutch plates.
|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.
644 RACE, FORWARD CLUTCH (OUTER) • Forw ard (650) and 3-4 clutch backing plates
(655) for:
Figure 66 Sprag Assembly Procedure - Flatness.
- Burrs or nicks.
• Forw ard clutch apply plate (646) and spacer
plate (647) for:
- Flatness.
- Burrs or nicks.
A PUSH IN AND TURN COUNTERCLOCKWISE TO INSTALL

644 RACE, FORWARD CLUTCH (OUTER) R H0162-4L60-E
Figure 67 Sprag Race and Retainer Assembly

Procedure
Figure 69 Forward and 3-4 Clutch Plates - Installed

Figure 68 Sprag Operation Check
• The 3-4 clutch apply plate (653) for:

- Flatness.
- Bent tangs.
|^ | Assemble
1. Forw ard clutch apply plate (646) into the input

clutch housing.
• Index as shown.
2. W aved steel forw ard clutch plate (648) into the
input clutch housing.
• Index as shown.
3. The rem aining forw ard clutch plates (649) into
654B
the input clutch housing.
• Start with a steel plate and alternate with
654A com position.
4. Forw ard clutch selective backing plate (650).
5. Forward clutch retaining ring (651).
Forward Clutch Piston Travel Check

F ig u re 7 2
[q I Measure
1. With the overrun clutch and forward clutch fully

assem bled in the Input Housing, check the end
clearance betw een the backing plate (650) and
the retaining ring (651) with two feeler gages.
2. Proper forw ard clutch backing plate travel
should be 0.75 to 1.60 mm (0.030 to 0.063
inch).
3. Select the proper backing plate from the chart
ILL. to obtain the correct clearance.
NO. DESCRIPTION
600 SPRING ASM., 3-4 CLUTCH BOOST (5)
621 HOUSING AND SHAFT ASSEMBLY, INPUT FORWARD CLUTCH INFORMATION CHART
646 PLATE, FORWARD CLUTCH (APPLY) QUANTITY REQUIRED
648 PLATE, FORWARD CLUTCH (WAVED) PLATE TYPE THICKNESS
649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL) ALL MODELS
649B PLATE, FORWARD CLUTCH (FIBER)
650 PLATE, FORWARD CLUTCH BACKING (SEL.) 4.30mm
APPLY PLATE 1
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER (.169")
653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER) WAVED STEEL 1.79mm
1
CLUTCH PLATE (-070")
654B PLATE, 3RD AND 4TH CLUTCH (STEEL)
655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.) FLAT STEEL 2.29mm
656 RING, 3RD AND 4TH CLUTCH BACKING PLATE CLUTCH PLATE 5
(.090”)
RETAINER
COMPOSITION
1.78mm
FACED CLUTCH 5
(0.70")
PLATES
BACKING PLATE SELECTIVE 1
RH0166-4L60-E
RH0165-4L60-E-R1
Figure 71 Forward Clutch Plate Chart
Figure 70 Input Housing with Forward and 3-4 Clutch
Plates
FORWARD CLUTCH 3-4 CLUTCH

BACKING PLATE SELECTION INFORMATION CHART
ALL MODELS QUANTITY REQUIRED
PLATE TYPE THICKNESS
BACKING PLATE TRAVEL = '? f oso^braT' ALL MODELS
PLATE THICKNESS IDENTIFICATION STEPPED 5.60mm

1
APPLY PLATE (.220")
6.97mm - 7.07mm A
(.274" - .278") t FLAT STEEL 1.78mm
1
6.38mm - 6.48mm CLUTCH PLATES (.070")
B
(.250" - .255")
FLAT STEEL 2.71mm
5.79mm - 5.89mm 5
C CLUTCH PLATE (.107")
(.227" - .232”)
5.20mm - 5.30mm D COMPOSITION
(.205" - .208“) 2.03mm
FACED CLUTCH 6
(0.79")
4.61mm - 4.71mm PLATES
E
(.180" - .185")
BACKING PLATE SELECTIVE 1
t SAME SPLINE CONFIGURATION AS APPLY PLATE
^ 651
650" \
RH0168-4L60-E-R1
^ J Figure 73 3-4 Clutch Plate Chart
3-4 Clutch Piston Travel Check

621 HOUSING AND SHAFT ASSEMBLY, INPUT Figure 74
650 PLATE, FORWARD CLUTCH BACKING (SEL.)
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER |^ | Measure
RH0167-4L60-E
• Check the end clearance betw een the backing
Figure 72 Forward Clutch Backing Plate Travel plate (655) and the first com position plate with
a feeler gage.
• Select the proper backing plate from the chart
3-4 Clutch Assembly to obtain the correct clearance for m odel you
are working on.
Figures 73 and 77
Assemble Clutch Air Check
1. The 3-4 clutch apply plate (653). Figure 75
• Index each leg into the apply ring legs. A ir check the 3-4, forw ard and overrun clutches
2. The 3-4 clutch plates (654). by applying air pressure at the feed holes in the turbine
• S ta rt w ith s te e l a n d a lte rn a te w ith shaft. (W hen the overrun clutch is checked, the air
com position as shown in (Figure 77). will blow by the forw ard clutch piston lip seals and
• F irs t ste e l p late has the sam e sp lin e exit out the forw ard clutch feed hole in the turbine
configuration as apply plate. shaft.)
3. The 3-4 boost springs (600).
4. The 3-4 clutch backing plate (655) and retainer
ring (656).
• C ham fered side up.
3-4 BACKING PLATE SELECTION
MODEL BACKING PLATE "BACKING

TRAVEL PLATE
Use Backing Plal e
Which Gives Correct Travel
DIM. I.D.
5.88mm - 5.68mm
A
(.231"-.224”)
2.10mm - .90mm 4.99mm - 4.76mm

ALL B
(.083" - .035") (.196“ -.187")
4.10mm - 3.90mm
C
(.161"-.154")

654 PLATE ASSEMBLY, 3RD AND 4TH CLUTCH
655 PLATE, 3RD AND 4TH CLUTCH
BACKING (SEL.)
RH0169-4L60-E-R1
Figure 74 3-4 Backing Plate Selection Chart
Turbine Shaft Seals

Figure 76
Tools Required:
J 36418-1 Seal Installer
619 RING, OIL SEAL (SOLID)
J 36418-2A Seal Sizer 621 HOUSING AND SHAFT ASSEMBLY, INPUT
R H0171-4L60-E
Assemble
Figure 76 Turbine Shaft Oil Seal Rings
1. Install four turbine shaft oil seal rings (619)
using J-36418-1.
Adjust
• A djust screw to obtain proper height.

U se J 3 6 4 1 8 -2 A to siz e th e se a ls a fte r
installation.
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
641 RETAINER AND RACE ASSEMBLY, SPRAG S H 0172-4L60-
Figure 77 Input Clutch Assembly
Reverse Input Clutch Assembly 2. Backing plate (613).

3. Clutch plates (612) and B elleville steel plate
(611).
Tools Required: 4. Install J 23327-1 and J 25018-A.
J 23327-1 Clutch Spring Com pressor • Com press the spring assembly.
J 25018-A C lu tch S pring C o m p resso r 5. Spring assem bly retainer ring (610) and spring
A daptor assem bly (609).
6. Reverse input clutch piston (607).
|fo | Disassemble
• Inner and outer lip seals (608).
1. Retaining ring (614) from reverse input

housing.
23327-1
614
613
J 25018-A
612B UNDER
J 23327-1
605 HOUSING AND DRUM ASSEMBLY,

REVERSE INPUT CLUTCH RH0174-4L60-E
Figure 79 Reverse Input Retainer Ring - Removal

612A
[ffi] Inspect
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.
• 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
Assemble 7. Backing plate (613).

• Cham fered side up
Figures 78, 79,81,82 and 83
1. Inner and outer seals (608) on the piston.
• Lips m ust face aw ay from the hub as Reverse Input Clutch Backing Plate Selection
shown.
• Lubricate with transm ission fluid.
2. Piston (607) into the housing and drum H |] Measure
assembly. 1. W ith the reverse input clutch fully assem bled,
• Use an 8 mm feeler gage to position the lip apply an evenly distributed load to the clutch
seals. pack in the direction show n in F igure 81.
• Use care not to dam age the seals. M edium pressure (approxim ately 89 N or 20
3. Spring assem bly (609). lbs.) on the backing plate applied by hand on
five evenly distributed points will obtain the
• Large opening in the assembly goes towards
backing plate travel for m easurem ent.
the piston.
4. Install J 23327-1 and J 25018-A. NOTICE: E xcessive pressure will distort the
A. Com press the spring assembly. B e lle v ille p la te re s u ltin g in an in a c c u ra te
m easurem ent.
B. Install the retainer ring (610).
5. Belleville steel clutch plate (611). 2. Using a feeler gage, m easure betw een the snap
ring and the backing plate. Backing plate travel
6. Clutch plates (612). (4 steel and 4 com position
should be 1.02 to 1.94 m m (0.040 to 0.076
plates required).
inch).
• S ta rt w ith a ste e l and a lte rn a te w ith
3. Select the proper backing plate to obtain the
composition.
specified travel.
REVERSE INPUT CLUTCH
NO. THICKNESS
2.311mm (.091")
BELLEVILLE PLATE 1
2.210mm (.087")
FLAT STEEL 2.045mm (0.81")

4
CLUTCH PLATE 1.892mm (0.75")
COMPOSITION FACED 1.880mm (.074")

4
CLUTCH PLATE 1.730mm (.068")
BACKING PLATE 1 SELECTIVE
R H0177-4L60-E
Figure 82 Reverse In pu t C lutch Plate C hart
REVERSE INPUT CLUTCH

BACKING PLATE SELECTION
ALL MODELS
„ . .___■_ 1.02mm - 1.94mm

BACKING PLATE TRAVEL = .0„
(0.40 - .076 )
PLATE THICKNESS IDENTIFICATION
7.249mm - 7.409mm 9
(.285" - .292")
6.678mm - 6.519mm q
o
(.263" - .257")
5.947mm - 5.787mm
(.234" - .228")
RH0178-4L60-E
Fiaure 83 Reverse Innut Rarkinq Plate Selection Chart

605 607 611 612A 612B

CORRECTLY

CLUTCH
607 PISTON ASM., REVERSE INPUT CLUTCH
609 SPRING ASM., REVERSE INPUT CLUTCH
610 RING, REVERSE INPUT CLUTCH SPRING RETAINER 615 BEARING ASSEMBLY, STATOR SHAFT/
611 PLATE, REVERSE INPUT CLUTCH (BELLEVILLE) SELECTIVE WASHER
612A PLATE ASM., REVERSE INPUT CLUTCH (FIBER) 616 WASHER, THRUST (SELECTIVE)
612B PLATE, REVERSE INPUT CLUTCH (STEEL) 621 HOUSING AND SHAFT ASSEMBLY, INPUT
613 PLATE, REVERSE INPUT CLUTCH BACKING (SELECTIVE)
614 RING, REVERSE INPUT CL. RETAINING
RH0179-4L60-E RH0180-4L60-E
Figure 84 Reverse Input Clutch Figure 85 Thrust Bearing and Selective Washer
Location
Reverse Input and Input Clutches

F ig u re s 8 5 , 8 6 a n d 8 7
|nfc| Assemble
1. Selective thrust w asher (616) onto the input

housing.
2. Bearing assem bly (615).
• Inside (black race) goes tow ard the oil
pump.
3. Reverse input clutch assem bly (605) onto the
input clutch assembly.
• Index the reverse input clutch plates with
the input clutch hub.
• M ake certain all clutch plates are fully
engaged.
605 HOUSING AND DRUM ASSEMBLY, REVERSE

INPUT CLUTCH
615 BEARING ASSEMBLY, STATOR SHAFT/
SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE)
R H0147-4L60-E
Figure 86 Reverse Input and Input Clutches

Assemble
F ig u re 8 7
• Reverse input and input clutch assem bly into

the transm ission case.
A. Index the 3-4 clutch plates with the input
internal gear.
B. M ake sure all c lu tc h p late s are fu lly
engaged.
C. W hen properly assembled, the reverse input
clutch housing will be located just below
the case oil pum p face.
602 BAND ASSEMBLY, 2-4
INPUT CLUTCH RH0182-4L60-E
Figure 88 2-4 Band A s s e m b ly - Installed
Oil Pump Assembly

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).
Oil Pump Body

F ig u re 9 1
A BAND ANCHOR PIN LOCATION

«£* Disassemble
41 PIN, BAND ANCHOR 1. Pum p slide springs (206 and 207).
INPUT CLUTCH
CAUTION: Springs are under very high
pressure. Place covering over spring to
R H0181-4L60-E
prevent possible injury.
Figure 87 In sta lling Input C lutch A. Com press with needle nose pliers.
B. Pull straight out.
2-4 Band Assembly
4 PUMP ASSEMBLY, OIL
F ig u re s 8 7 a n d 8 8 601 WASHER, THRUST
(PUMP TO DRUM)
[y | Inspect
• 2-4 band assem bly (602) for dam age or wear.
|^ | Assemble
1. Align the band anchor pin end with the case

pin hole.
2. Band anchor pin (41) into the case. R H0183-4L60-E
• Index the pin into the 2-4 band.
Figure 89 Oil Pump Thrust Washer Location
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
• Pressure regulator valve assembly (216-221) and

converter clutch apply valve assembly (222-226)
for:
- Chips, burrs, distortion, plugged oil passage
and free m ovem ent in bore.
- Rem ove burrs with lapping compound.
203 SLIDE, PUMP
• Pressure relief assem bly (227-229) for dam age 212 ROTOR, OIL PUMP
or distortion.
R H0184-4L60-E
Figure 90 Oil Pump Rotor and Slide Selection

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
Figure 91 Oil Pump Assembly

||j|| Measure 8. Vanes (213).

9. Vane guide ring (210).
Figure 90
10. Pum p slide spring (206 and 207).
• Oil pum p rotor (212) thickness. 11. Oil seal assem bly (2), retainer (94).
• Oil pum p slide (203) thickness. • Use J 25016.
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.
Oil Pump Body

Tool Required:
Assemble
1. O-ring seal (202) and oil seal ring (201) into

the groove on the back side of the slide.
• R e ta in w ith T ra n s je l™ J 3 6 8 5 0 or
equivalent.
2. Pivot pin spring (204) and pivot pin (205) into
the pum p body. 201 RING, OIL SEAL (SLIDE TO WEAR PLATE)
3. Slide (203). 202 SEAL, O-RING (SLIDE SEAL BACK-UP)
• Index the notch in the slide with the pivot
pin. 208 SUPPORT, PUMP SLIDE SEAL
• The oil seal ring m ust face dow nw ard into 209 SEAL, PUMP SLIDE
S H 0187-4L60-E
the pum p pocket.
4. Slide seal (209) and support (208). Figure 93 Slide Back Up and Slide Seal
5. Vane guide ring (210).
6. Rotor guide (211) onto the rotor. Oil Pump Cover
• R e ta in w ith T ra n s je l™ J 3 6 8 5 0 o r Figure 91
equivalent.
7. Rotor (212). Assemble
• W ith guide tow ard the pum p pocket. 1. Pressure relief ball (228), spring (229) and rivet
(227).
2. Inner (225) and outer (226) converter clutch
valve springs into the converter clutch valve
bore.
3. C onverter clutch valve (224).
4. Stop valve (223).
6. Pressure regulator valve (216) into the pressure
regulator bore.
7. Pressure regulator valve spring (217).
Figure 92 HYDRA-MATIC 4L60-E - Oil Pump Seal

8. Reverse boost valve (219) into the reverse boost

valve sleeve.
• Small end of the valve first
equivalent.
9. R everse b o o st valve sleeve (220) into the
pressure regulator bore.
10. Retainer ring (221).
Oil Pump Cover and Body

Figures 91 and 95 through 98
Tools Required:
J 2 1 3 6 8 O il P u m p B o d y and C o v e r
A lignm ent Band
J 25025-1 A lignm ent Pins
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.).
equivalent.
4. Install two oil seal rings (233) using J38735-3
and J 39855-1.
j9 Adjust
• A djust screw to obtain proper height.

5. Use J 39855-2 to size seals after installation.

RETAINING
222 RING, OIL PUMP CONVERTER CLUTCH VALVE RETAINING
223 VALVE, STOP
RH0188-4L60-E
Figure 94 Pressure R egulator and C onverter Clutch

Apply Valve Trains
| 9 | Important
• Rotate the transm ission to a horizontal position.

If the transm ission is assem bled properly the
turbine shaft should turn by hand. If not identify
and correct the m isassem bly now.
J 21368
RH0189-4L60-E
Figure 95 Oil Pump Alignment Band
Transmission End Play Check

Figures 99 through 103 and 106, 107 and 108
Tools Required:
J 24773-A End Play Checking Fixture
J 25022 End Play Checking Fixture Adaptor
(245 mm)
|-»<-| Install or Connect J 34725 End Play Checking Fixture Adaptor
(298 mm)
Figure 98
J 25025-7A Post or 278 mm (11 inch) Bolt
1. Thrust w asher (601). and Nut
2. J 25025-1 into the case as shown. Dial indicator
3. Oil pum p assem bly into the case.
• Align all holes properly. 11§| Measure
4. Bolts and O-rings (2 and 3). Figures 99 through 102
[^ ] Tighten 1. Rem ove an oil pum p to case bolt and install a
278 mm (11 inch) bolt and lock nut or J 25025-
• Bolts to 24 N»m (18 lb. ft.). 7A.
2. Install J 25022-A or J 34725 as shown.
3. Install J 24773-A as shown.
4. Install a dial indicator.
• Set to zero.
5. Pull up on J 24773-A.
• End play should be 0.13 to 0.92 mm (0.005
to 0.036 inch).
The selective washer which controls end play is
located betw een the input housing and the thrust
bearing on the oil pum p hub. If m ore or less end play
is required, select the proper w asher from the chart
and install. If dial indicator shows no end play, the
se le c tiv e w ash er and th ru st b earin g hav e been
m isassem bled.
TRANSMISSION END PLAY

WASHER SELECTION CHART
WASHER THICKNESS I.D.
1.87 - 1.97 mm (.074" - .078") 67

2.04 - 2.14 mm (.080" - .084") 68
2.21 - 2.31 mm (.087" - .091") 69
2.38 - 2.48 mm (.094" - .098") 70
2.55 - 2.65 mm (.100" - .104") 71
2.72 - 2.82 mm (.107" - .111") 72
2.89 - 2.99 mm (.113" - .118") 73
3.06 - 3.16 mm (.120"- .124") 74
RH0192-4L60-E
Figure 101 End Play Chart
CORRECTLY
A 298mm TURBINE SHAFT
B 245mm TURBINE SHAFT
RH0114-4L60-E
Figure 99 End Play Tool
615 BEARING ASSEMBLY, STATOR SHAFT/

SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE)
RH0180-4L60-E
Figure 100 J 25022-A Installed Figure 102 Selective Washer and Thrust Bearing
Properly Installed
|^ | Assemble [y | Inspect
Figure 103 Figures 105, 106 and 107

• O-ring seal (618) into the groove in the end of • The 1-2 accum ulator cover and pin assem bly
the turbine shaft. (57) for:
- Porosity or damage.
[Y ] Important
- Scored piston wall.
• There should be clearance betw een the reverse - Plugged oil passage.
input clutch and the reaction sun gear shell.
• 1-2 a c c u m u la to r p isto n (56) and th e 3-4
This clearance can be observed at the point
accum ulator piston (44) for:
shown in Figure 105. Do not try to shim the
internal parts because of this clearance (Figure - Porosity.
104). - Ring groove damage.
- Pin hole damage.
• 1-2 accumulator spring (54) and 3-4 accum ulator
spring (46) for distortion or damage.
• Spacer plate (48) and gaskets (47 and 52) for
damage.
• Checkballs (61) for damage.
• M anual detent spring (63) for damage.
• Oil filter (72) for:
- Cut or dam aged filter seal (71).
- Cracks in the neck or body.
- Casting flash in the neck.
USED WITH USED WITH
298mm CONVERTER 245mm CONVERTER • Solenoid assem bly (66) for:
- Damage.
A SHAFT, TURBINE
618 SEAL, O-RING (TURBINE SHAFT/SELECTIVE WASHER) - Cut or pinched wires.
- D am aged connectors.
RH0152-4L60-E
- Cut or dam aged O-ring (65).
A AS INSTALLED THESE TWO PARTS HAVE A NORMAL

END CLEARANCE OF APPROX. 3.8mm (.150")
8 CASE TRANSMISSION
CLUTCH
670 SHELL, REACTION SUN RH0193-4L60-E
Figure 104 Clearance Between Reverse Input Clutch

and Sun Gear Shell
1-2 A C C U M U LA T O R SPRING COLOR
1994 M O D ELS INNER OUTER
CA, CB, CH, CJ, CP, FD,

KA, KC, M D , M J , M N , M S , NO P A IN T Y ELLO W
SF, SH, TA , TB, TL, T W
CC, CF, CM , CU, PINK YE LLO W

KB, KP
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
A H , BF, BW ORAN G E Y E LLO W
FF, YD W H ITE DK GREEN
3-4 A C C U M U LA T O R SPRING COLOR
1994 M O D E LS COLOR
CA, CB, FD, FF, HB, HD,

KA, M D , M J , M M , M S , LT BLUE
SF, SH, T A , TB, TL, T W , YD
C M , CU, KP RED
BB, BC DK GREEN
A H , BF, BW VIO LET
CC, CF, CH, CJ,

CP, KB, KC, S A NOT USED
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.
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.
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).
Fgl Clean |iy | Clean
• 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).
• Be careful not to dam age screens when

installing the valve body assembly.
3. W iring harness (66), m anual spring assem bly
(63), pressure switch assem bly (69), dipstick
stop bracket (93) and all rem aining valve body
bolts.
NOTICE: Tor que valve body bolts in a spiral

pattern starting from the center. If bolts are torqued
at random , valve bores m ay be distorted and
inhibit valve operation.
4. TCC solenoid (66) and bolts (68).

f^ l Tighten
• Bolts to 11 N*m (8 lb. ft.)
5. TCC PW M solenoid (396), and retainer clip
(379).
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
Figure 108 Filter Screen - Locations

Figure 109 Control Valve Assembly

340 VALVE, MANUAL

353 SEAL, FORWARD ACCUMULATOR OIL
354 PISTON, FORWARD ACCUMULATOR
355 PIN, FORWARD ACCUMULATOR
356 SPRING, FORWARD ACCUMULATOR
357 VALVE, FORWARD ABUSE
358 SPRING, FORWARD ABUSE VALVE
359 PLUG, BORE
360 PIN, COILED SPRING
361 VALVE, LOW OVERRUN
362 SPRING, LOW OVERRUN VALVE
363 COVER, FORWARD ACCUMULATOR
365 SPRING, 1-2 SHIFT VALVE
366 VALVE, 1-2 SHIFT
367A 1-2 SHIFT SOLENOID (A)
367 B 2-3 SHIFT SOLENOID (B)
369 VALVE, 2-3 SHUTTLE
370 SPRING, 1-2 ACCUMULATOR VALVE
371 VALVE, 1-2 ACCUMULATOR
372 SLEEVE, 1-2 ACCUMULATOR VALVE
373 PLUG, BORE
374 VALVE, ACTUATOR FEED LIMIT
375 SPRING, ACTUATOR FEED LIMIT VALVE
376 PLUG, BORE
377 PRESSURE CONTROL SOLENOID
378 RETAINER, PRESSURE CONTROL SOLENOID
380 VALVE, REGULATOR APPLY
381 PLUG, BORE
382 SPRING, 4-3 SEQUENCE VALVE
383 VALVE, 4-3 SEQUENCE
384 VALVE, 3-4 RELAY
387 VALVE, REVERSE ABUSE
388 SPRING, REVERSE ABUSE VALVE
389 VALVE, 3-2 DOWNSHIFT
390 SPRING, 3-2 DOWNSHIFT VALVE
391 VALVE, 3-2 CONTROL
392 SPRING, 3-2 CONTROL VALVE
393 SPRING, BORE PLUG
394 3-2 CONTROL SOLENOID
395 RETAINER, BORE PLUG
397 SPRING, REGULATOR APPLY
398 VALVE, ISOLATOR
SH0196-4L60-E
Figure 110 Control Valve Assem bly - Legend


340 VALVE, MANUAL RH0110-4L60-E
Figure 112 Manual Valve Link
#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
Figure 111 Valve Body Checkball Locations
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 113 Valve Body Bolt Locations

66 SOLENOID ASSEMBLY, WIRING HARNESS 72 FILTER ASSEMBLY, TRANSMISSION OIL

73 GASKET, TRANSMISSION OIL PAN
75 PAN, TRANSMISSION OIL
SH0198-4L60-E 76 SCREW, TRANSMISSION OIL PAN SH 0240-4L60-E
Figure 114 Outside Electrical Connector Figure 115 Case, Pan and Filter Assembly
|-»<-| Install or Connect 2-4 Servo Assembly

Figure 115 Figures 116 through 120
1. Filter seal (71) into the pump. Tools Required:
2. Oil filter (72). J 33037 Band Apply Pin Tool
3. Oil pan gasket (73). Vernier calipers
4. Chip m agnet (74) onto oil pan (75). Scale
5. Oil pan (75) and bolts (76). J 22269-01 Piston Com pressor
\q \ Tighten J 29714 Servo Cover C om pressor
• Torque to 12 N*m (9 lb. ft.)
|i| Measure
Figure 116
1. Install J 33037 as shown with apply pin (13).
2. Install servo cover retaining ring (29) to secure
tool.
3. Apply 11 N*m (98 lb. in.) torque.
4. If white line “A ” appears in the gage slot “B ”,
pin length is correct.
5. U se pin selection chart to determ ine the correct
pin length if new pin is needed.
[y | Inspect | |i|| Measure

• Pistons for: Figure 117
- Porosity or damage. 1. M easure piston (17) dim ension *A.
- Ring groove damage. 2. M easure housing (20) dim ension **B.
3. C heck m odel application.
PIN IS PRESET AT FACTORY AND MUST NOT BE

READJUSTED
2-4 SERVO PIN SELECTION
PIN LENGTH PIN I.D.
MM INCH
65.82-66.12 2.59-2.60 1 GROOVE

67.23-67.53 2.65-2.66 2 GROOVES
68.64-68.94 2.70-2.71 NO GROOVE
RH0102-4L60-E
Figure 116 Servo Pin Length
• Cover (28) for porosity or damage.

• Seals for:
- Nicks or cuts.
- Freeness in the seal groove.
• Springs for distortion.
• Pin for w ear or burrs.
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.
|jjtj Assemble
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).
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).
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
Figure 118 2-4 Servo Assem bly

3. Seal ring (37) on the case extension.

4. Case extension (31) and bolts (32).
J 29714
• Position extension so the speed sensor bore
is on the gear selector lever side o f the
case.
Hx] Tighten
• Torque to 35 N»m (26 lb. ft.).
5. Rem ove case extension oil seal (34).
A. Pry out with a screwdriver.
B. Install new seal w ith J 21426.
6. Speed sensor (36) w ith J 38417.
7. Retainer, bolt and w asher (34).
8. Outside electrical connector, gear selector lever
and nut.
20 HOUSING, SERVO PISTON

(INNER)
12 SPRING, SERVO RETURN 21 SEAL, O-RING
13 PIN, 2ND APPLY PISTON 22 SPRING, SERVO APPLY PIN
14 RING, RETAINER (2ND 23 WASHER, SERVO APPLY
APPLY PISTON) PIN
15 RETAINER, SERVO 24 RING, RETAINER (APPLY
CUSHION SPRING PIN)
16 SPRING, SERVO CUSHION 25 PISTON, 4TH APPLY
17 PISTON, 2ND APPLY 28 COVER, 2-4 SERVO
18 RING, OIL SEAL (2ND 29 RING, SERVO COVER
APPLY PISTON - OUTER) RETAINING
19 RING, OIL SEAL (2ND
APPLY PISTON - INNER) RH0101-4L60-E
Figure 121 Output Shaft Sleeve and Seal
Figure 120 2-4 Servo Bore
Speed Sensor and Case Extension

Figures 123
Tools Required:
J 23103 or J 25016 Seal Installer
J 3 8 4 1 7 S p e e d S e n s o r R e m o v e r an d
Installer
p>| Install or Connect
1. O-ring seal (691) on the output shaft sleeve.

2. Output shaft sleeve (690) on the output shaft.
• Use J 25016 or J 23103.
• Do not push the sleeve past the m achined
surface on the output shaft.

31 EXTENSION, CASE
32 BOLT, CASE EXTENSION TO CASE R H0202-4L60-E
Figure 123 Case Extension and Seal
Torque Converter Assembly

Figure 126
Tool Required:
J 35 1 3 8 T o rq u e C o n v e rte r E nd P lay
Checking Tool
[jF^] Inspect
The torque converter assem bly m ust be replaced

for any of the follow ing conditions:
• Evidence o f dam age to the pum p assembly.
• M etal particles are found after flushing the
cooler and cooler lines.
ILL. • External leaks in hub weld area.
NO. DESCRIPTION
• Converter pilot is broken, dam aged or poor fit
8 CASE, TRANSMISSION into crankshaft.
31 EXTENSION, CASE • Converter hub is scored or damaged.
32 BOLT, CASE EXTENSION TO CASE • Internal dam age to stator.
33 BUSHING, CASE EXTENSION
34 SEAL ASSEMBLY, CASE EXTENSION OIL
• Contam ination from engine coolant.
35 BOLT, SPEED SENSOR RETAINING • Excess end play.
36 SPEED SENSOR, INTERNAL TRANSMISSION
37 SEAL, O-RING (ITSS TO CASE EXTENSION) ||H | Measure
687 SHAFT, OUTPUT
RH0106-4L60-E
Figure 126
Figure 124 Case Extension and Associated Parts • Install J 35138 and m easure end play.
- 0 to 0.5 mm (0.000 to 0.020 inch) for
245 mm torque converters.
- 0 to 0.6 mm (0.000 to 0.024 inch) for
298 mm torque converters.
The Torque Converter should not be replaced If:

• The fluid has an odor, discoloration or no
evidence o f m etal or clutch plate material.
A. Drain out as m uch fluid as possible.
B. Replace the oil filter and pan gasket.
C. Fill to proper level (Refer to Section 7A).
• The converter bolt hole threads are damaged.
- Correct with thread insert (Refer to Section
6A).
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
Figure 126 Checking Torque Converter End Play

HYDRA-MATIC 4L60-E
CASE REVERSE IN P U T CLUTCH O VER R UN FO RW A RD FO RW ARD 3-4 IN P U T LO A N D LO ROLLER REACTION OUTPUT
ASSEM BLY IN P U T CLUTCH H O U S IN G C LU TC H CLUTCH SPRAG CL CLUTCH P LA N E TA R Y REVERSE CLUTCH P LA N E TA R Y S H AFT
Figure 127 HYDRA-MATIC 4L60-E Transmission
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

7A-14B-61
TU R B IN E CONVERTER ROLLER PUM P BAND INSIDE MANUAL C O N TR O L VALV E PAR KIN G LOCK PAR KIN G SPEED
SH A F T ASSEM BLY CLUTCH A S S E M B LY ASSEM BLY D ETEN T LEVER S H A FT ASSEM BLY A C TU A TO R A S S E M B L Y PAW L SENSOR
Figure 128 Case and Associated Parts

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
Figure 129 Case and Associated Parts - Legend

Figure 130 Transmission Internal Parts

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
Figure 131 Transmission Internal Parts - Legend

S H 0195-4L60-E
Figure 132 Control Valve Assembly

340 VALVE, MANUAL

353 SEAL, FORWARD ACCUMULATOR OIL
354 PISTON, FORWARD ACCUMULATOR
355 PIN, FORWARD ACCUMULATOR
356 SPRING, FORWARD ACCUMULATOR
357 VALVE, FORWARD ABUSE
358 SPRING, FORWARD ABUSE VALVE
359 PLUG, BORE
360 PIN, COILED SPRING
361 VALVE, LOW OVERRUN
362 SPRING, LOW OVERRUN VALVE
363 COVER, FORWARD ACCUMULATOR
367A 1-2 SHIFT SOLENOID (A)
367B 2-3 SHIFT SOLENOID (B)
369 VALVE, 2-3 SHUTTLE
370 SPRING, 1-2 ACCUMULATOR VALVE
371 VALVE, 1-2 ACCUMULATOR
372 SLEEVE, 1-2 ACCUMULATOR VALVE
373 PLUG, BORE
374 VALVE, ACTUATOR FEED LIMIT
375 SPRING, ACTUATOR FEED LIMIT VALVE
376 PLUG, BORE
378 RETAINER, PRESSURE CONTROL SOLENOID
380 VALVE, REGULATOR APPLY
381 PLUG, BORE
382 SPRING, 4-3 SEQUENCE VALVE
383 VALVE, 4-3 SEQUENCE
384 VALVE, 3-4 RELAY
387 VALVE, REVERSE ABUSE
388 SPRING, REVERSE ABUSE VALVE
389 VALVE, 3-2 DOWNSHIFT
390 SPRING, 3-2 DOWNSHIFT VALVE
391 VALVE, 3-2 CONTROL
392 SPRING, 3-2 CONTROL VALVE
393 SPRING, BORE PLUG
394 3-2 CONTROL SOLENOID
395 RETAINER, BORE PLUG
397 SPRING, REGULATOR APPLY
398 VALVE, ISOLATOR
SH0196-4L60-E
Figure 133 Control Valve Assem bly - Legend

VALVES LOCATED IN THE PUMP VALVES LOCATED IN THE VALVE BODY
FORWARD ABUSE LO OVERRUN
1-2 ACCUM VALVE ACTUATOR FEED LIMIT
1-2 SHIFT VALVE
3-2 DOWNSHIFT REV ABUSE
war im ■■ 3-4 SHIFT VALVE
2-3 SHUTTLE VALVE 2-3 SHIFT VALVE
3-2 CONTROL
4-3 SEQUENCE VALVE
MANUAL VALVE
SH 0209-4L60-E
Figure 134 Control Valve Identification

SPRINGS LOCATED IN THE PUMP SPRINGS LOCATED IN THE VALVE BODY
PRESSURE 1-2 3-4

REGULATOR ACCUM SHIFT
REGULATOR
APPLY
3-2 ACT 1-2

DOWNSHIFT FD LIMIT SHIFT
BLU
PUR
3-2 LOW FWD REV

CONTROL OVERRUN ABUSE ABUSE
S H 0210-4L60-E
Figure 135 Control Valve Spring Identification

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
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
RETAINING
222 RING, OIL PUMP CONVERTER CLUTCH VALVE
RETAINING
223 VALVE, STOP
227 RIVET, PRESSURE RELIEF BOLT
228 BALL, PRESSURE RELIEF
229 SPRING PRESSURE RELIEF
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)
244 RETAINER, FRONT HELIX
SH 0185-4L60-E
Figure 136 Oil Pump Assembly

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)
608 SEALS, REVERSE INPUT CLUTCH (INNER AND
OUTER)
S H 0211-4L60-E
Figure 137 Seal Locations

7 BUSHING, CASE 657 BUSHING, INPUT SUN GEAR (FRONT)

33 BUSHING, CASE EXTENSION 659 BUSHING, INPUT SUN GEAR (REAR)
234 BUSHING, STATOR SHAFT (FRONT) 663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
241 BUSHING, STATOR SHAFT (REAR) REACTION SHAFT)
242 BUSHING, OIL PUMP BODY 665 BUSHING, REACTION CARRIER SHAFT (FRONT)
601 WASHER, THRUST (PUMP TO DRUM) 667 BUSHING, REACTION CARRIER SHAFT (REAR)
669 WASHER, THRUST (REACTION SHAFT/SHELL)
603 BUSHING, REVERSE INPUT CL. (FRONT)
672 BUSHING, REACTION SUN
606 BUSHING, REVERSE INPUT CLUTCH (REAR)
615 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE
WASHER
616 WASHER, THRUST (SELECTIVE) SUPPORT)
637 692 BEARING., REACTION GEAR SUPPORT TO CASE
BEARING ASSEMBLY, INPUT SUN GEAR
SH 0212-4L60-E
Figure 138 Bushing and Bearing Locations

TORQUE SPECIFICATIONS
LOCATION QTY. SIZE TORQUE LOCATION QTY. SIZE TORQUE

ACCUMULATOR M6 11 N*m PARK BRAKE M8 31 N-m
2 2
COVER TO CASE 1.0x35.0 (8 LB.-FT.) BRACKET TO CASE 1.25 X 20.0 (23 LB.-FT.)
ACCUMULATOR M6 11 N-m PUMP COVER TO M8 24 N-m
1 5
COVER TO CASE 1.0x65.0 (8 LB.-FT.) BODY 1.25 X 40.0 (18 LB.-FT.)
DETENT SPRING TO M8 24 N-m PUMP ASSEMBLY TO M8 24 N-m
1 7
VALVE BODY 1.25x 20.0 (18 LB.-FT.) CASE 1.25 X 60.0 (18 LB.-FT.)
FWD ACCUM. COVER M6 11 N-m CASE EXTENSION M10 35 N-m
3 4
TO VALVE BODY 1.0 x 17.7 (8 LB.-FT.) TO CASE 1.50 X 30.0 (26 LB.-FT.)
SOLENOID ASSEMBLY M6 11 N-m MANUAL SHAFT TO M10 31 N-m
2 1
TO CASE 1.0 x 12.0 (8 LB.-FT.) INSIDE DETENT LEVER 1.50 NUT (23 LB.-FT.)
TRANSMISSION OIL M8 11 N-m LINE PRESSURE 11 N-m
16 1 1/8 - 27
PAN TO CASE 1.25 x 19.3 (8 LB.-FT.) PLUG (8 LB.-FT.)
VALVE BODY M6 11 N-m CONNECTOR COOLER 38 N-m
2 2 1/4 - 18
TO CASE 1.0 X 35.0 (8 LB.-FT.) PIPE (28 LB.-FT.)
VALVE BODY M6 11 N-m PRESSURE SWITCH M6 11 N-m
9 2
TO CASE 1.0 x 47.5 (8 LB.-FT.) ASM. TO VALVE BODY 1.0 X 17.7 (8 LB.-FT.)
VALVE BODY M6 11 N-m VEHICLE SPEED M6 11 N-m
3 1
TO CASE 1.0 x 54.4 (8 LB.-FT.) SENSOR RETAINER 1.0 X 21.7 (8 LB.-FT.)
VALVE BODY M6 11 N-m SPACER PLATE M6 11 N-m
3 3
TO CASE 1.0 x 65.0 (8 LB.-FT.) SUPPORT TO CASE 1.0 X 17.7 (8 LB.-FT.)
PRESSURE CONTROL
M6 11 N-m
SOLENOID TO 1
1.0 X 17.7 (8 LB.-FT.)
VALVE BODY
R H0235-4L60-E
Figure 139 Torque Specifications

BUSHING REPLACEMENT PROCEDURE

PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY
REMOVE AS SHOWN INSTALL AS SHOWN
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
Figure 140 Bushing Replacement Procedure


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
Figure 143 Special Tools

SPECIAL TOOLS
SPEED SENSOR ROTER SPEEDOMETER GEAR HANDLE INNER FORWARD CLUTCH
INSTALLER INSTALLER SEAL PROTECTOR
J 36352-4 & J 36352-6 J 5590 J 8092 J 29883

2-4 BAND APPLY PIN TOOL DIAL INDICATOR POST END PLAY CHECKING TOOL INNER OVERRUN CLUTCH
SEAL PROTECTOR
J 33037 J 26900-13 J 35138 J 29882

STATOR SHAFT SEALS INSTILLATION AND SIZING TOOLS BUSHING INSTALLERS
J 39855-1 J 38735-3 J 39855-2 J 25019-12

Pusher J 25019-9
P ro te c to r S izer
J 39855-1 & J 38735-3 & J 39855-2 J 25019-9 & J 25019-12

BUSHING REMOVER BUSHING REMOVER BUSHING REMOVER BUSHING REMOVER
J 25019-14 J 24036 J 23062-14 J 25019-16

BUSHING SET COOLER FLUSHER
J 34196
DIAL INDICATOR STAND & GUIDE PIN SET
_____ ____________ zm
a m ...............................' - i - m io “ 3 * « « « - — ' ---r-flM D
BMW---------- — '- - = n tM ) - H im i n - - , ......- - M D
I J 35944
RH0236-4L60-E
J 25025-B
Figure 144 Special Tools
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
GENERAL SERVICE INFORMATION HOLDING FIXTURE

• M ake sure the work area is adequate and CLEAN Figure 1
for the layout and inspection of components. Tools Required:
• Replace Teflon® seal rings if cut, damaged or do
J 3289-20 Base
not rotate freely in their groove or if performing
complete overhaul. J 8763-02 Holding Fixture
• Inspect all seal ring grooves for debris, burrs or J 38655 Adapter
damage.
• A lw ay s lu b ric a te b o lt/sc re w th re a d s w ith p7| Install or Connect
transm ission fluid p rio r to in stallation into 1. H olding fixture J 8763-02 and J 38655 onto
aluminum. transmission.
• Thrust washer and bearing surfaces may appear
to be polished, this is a normal condition and
NOTICE: Overtightening o f tool could cause case
should not be considered damaged. damage and inhibit disassembly.
• D o n o t o v e r e x p a n d sn ap rin g s d u rin g 2. T ra n sm iss io n an d h o ld in g f ix tu re in to
disassembly or assembly. J 3289-20.
• Replace A L L seals on components that have 3. Lock in place with fixture pin.
been disassembled.
|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
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
1. Two Speed Sensor Assemblies (22) and two bolts

(23) with 8 mm socket.
3. Pan (28), seal (29) and m agnet (30).

ff] Important
• Seal (29) is reusable.

4. Filter assembly (31).
03 Inspect
• Filter neck seal (32), replace if necessary.
WIRE HARNESS ASSEMBLY

Figure 3
[*"»| Remove or Disconnect
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.
27 BOLT, HEX FLANGE HD (PAN TO CASE) 31 FILTER ASSEMBLY, TRANSMISSION OIL

28 PAN, TRANSMISSION OIL 32 SEAL ASSEMBLY, FILTER NECK
29 SEAL, TRANS. OIL PAN 33 CLAMP, ELECTRICAL CABLE
30 MAGNET, CHIP COLLECTOR 34 HARNESS ASSEMBLY, ELECTRICAL WIRING
35 BOLT, HEX HD. - M6 X 1.0X55.0 S H 0102-4L80-E
Figure 3 Pan, Filter and Seal Removal


Figure 4
1. Rotate transmission bottom pan surface up and

lock in place.
2. Wire harness assem bly (34) connectors from
components.
Important
• If the wire harness assembly does not need

servicing, it is not necessary to remove it
from the case.
• Use a cap to cover electrical pin at case
connection.
3. Six b o lts (7 6 ) u sin g 8 m m s o c k e t, and
transmission fluid pressure switch assembly (40).
NOTICE: Be sure five O-rings are attached to
transmission fluid pressure switch assembly.
4. Twenty-one bolts (35) using 10 mm socket, from
valve body assembly, manual detent spring and
roller assembly (41).
5. Three wiring clamps (33), fluid level indicator
stop (43), one bolt (36) using 10 mm socket,
lube pipe (39), lube pipe retainer (37) and clamp
(38).
6. C ontrol valve assem bly (44) including the
accum ulator housing assembly (51), valve body
gaskets (45 and 48), spacer plate (46) and
accum ulator gasket (47).
7. Manual valve (319) from control valve assembly
(44) to prevent any damage.
8. Checkballs (54) from case passages.
NOTICE: Do not use a magnet. It could cause
checkball(s) to be m agnetized causing m etal
particles to stick to the ball.
9. Pulse Width M odulated (PW M) solenoid screen
(75).
33 CLAMP, ELECTRICAL CABLE
34 HARNESS ASSEMBLY, ELECTRICAL WIRING
Inspect 35 BOLT, HEX HD. - M6 X 1.0X55.0
36 BOLT, M 6X 1.0X35.0 LG V.B. TO C.P.
• Screen PW M solenoid (75), replace if 37 RETAINER, LUBE PIPE
necessary. 38 CLAMP, LUBE PIPE
39 PIPE, LUBE
40 SWITCH ASM., A/TRANS. FLUID PRESS.
43 STOP, FLUID LEVEL INDICATOR (DIPSTICK)
44 BODY ASSEMBLY, CONTROL VALVE
51 HOUSING, ACCUMULATOR
75 SCREEN, PWM SOLENOID
76 BOLT, SPECIAL
S H 0103-4L80-E
Figure 4 Removing Control Valve Assem bly

FRONT AND REAR SERVO

Figures 5 and 6
1. Front servo piston assembly (55 through 60).

2. Six rear servo bolts (61) using 10 mm socket,
cover (62) and gasket (63).
3. Rear servo/accumulator assembly (64 through
74).
61 BOLT, REAR SERVO COVER

62 COVER, REAR SERVO
63 GASKET, REAR SERVO COVER
64 CLIP, RETAINING (BOTTOM)
65 PISTON, REAR SERVO
66 RING, OIL SEAL ACCUM. PISTON (OUTER)
67 RING, OIL SEAL ACCUM. PISTON (INNER)
68 PISTON, REAR ACCUMULATOR
69 SEAL, REVERSE SERVO PISTON
70 WASHER, SERVO PISTON
71 SPRING, REAR SERVO
72 RETAINER, REAR PISTON SPRING
73 PIN, REAR BAND APPLY (SELECTIVE)
74 SPRING, REAR ACCUMULATOR RH0105-4L80-E
Figure 6 Removing Rear Servo Assembly

SERVO PIN CHECK

Figures 7,8 and 9
Tools Required:
J 21370-10 Gage Pin
J 38737 Servo Pin Checking Tool
|^ | Measure
1. Place J 21370-10 in the servo bore.

2. Position J 38737 over the bore with the hex nut
facing the parking pawl linkage.
3. Fasten with two rear servo cover bolts (61) and
torque to 24 N«m (18 lb. ft.).
4. M ake sure J 21370-10 gage pin moves freely in
the tool and pin bore.
5. To determine correct pin length apply 34 N*m
(25 lb. ft.) torque to the nut on the gage.
6. For pin selection, see Figure 9.
Figure 9 Servo Pin Selection Chart
J 2 1 3 7 0 -1 0 ^ ^
B C
u RH0107-4L80-E
Figure 8 Gage Pin

CASE EXTENSION ASSEMBLY PARKING LOCK PAWL AND ACTUATOR

Figure 10 ASSEMBLY
Figures 11 and 12
p7| Remove or Disconnect
1. Six bolts (21) using 15 mm socket and extension NOTICE: Do not apply excessive force, prying,
assembly (19). or hamm ering to any parking mechanism parts,
doing so could cause parking system failure.
2. O-ring Seal (15).
[y | Inspect E
• O u tp u t shaft O -ring seal (675) (som e 1. Nut (712) using 15 mm wrench and pin (709).
models) for damage. 2. Detent lever (711) and actuator assembly (710).
3. Bolts (714) using 13 mm socket and parking
pawl bracket (713).
4. Spring (705).
5. Plug (701) using screw extractor.
6. Parking pawl shaft retainer (704), shaft (702)
and pawl (703).
7. Seal (707) and manual shaft (708).
12 CUP, ORIFICE W/SEAL/PLUG-REAR LUBE (4WD)

13 SEAL ASSEMBLY, REAR LUBE
14 RING, SNAP SEAL RETAINER
15 SEAL, EXTENSION TO CASE
19 EXTENSION ASSEMBLY, CASE
20 HELIX SEAL ASSEMBLY, CASE EXTENSION
21 BOLT, HEX H D -M 1 0 X 1.5X30.0
675 SEAL, O-RING OUTPUT SHAFT
RH0109-4L80-E
Figure 10 Case Extension and Associated Parts

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
Figure 11 R em oving Parking Lock and A c tu a to r A sse m bly
FOR MODELS
EQUIPPED WITHOUT
NSBU SWITCH
708 SHAFT, MANUAL S H 0111-4L80-E
Figure 12 Parking Lock and Actuator Assembly

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
• During reassembly Front End Play Check must

be repeated to verify accuracy o f selective
1. Attach J 8001 rod to one of the bolt holes on the washer.
transmission case (7).
2. M ount J 8001 on the rod and index it to the end
of the turbine shaft. Set dial to “0”.
3. Eliminate slack by pressing down on turbine shaft THICKNESS (INCH) STRIPE
(502) and with J 28585 up on output carrier,
.057 - .061 BLUE
then pull up with 3 to 5 lbs. of force on turbine
shaft to eliminate any clearance between snap .073 - .077 RED
ring (522) and overdrive carrier (514). .089 - .093 BROWN
.105- .109 GREEN
.121 - .125 PLAIN
J 8001
RH0113-4L80-E
Figure 14 Selective Thrust Washer Chart
REAR UNIT END PLAY CHECK

Figures 15 and 16
Tool Required:
J 8001 Dial Indicator Set
Measure
1. Attach J 8001 rod to one of the bolt holes at the

end of the transmission case (7).
2. Push in on output shaft (671) to take up any
slack.
J 28585 3. M ount J 8001 on the rod and index it to the end
of the output shaft. Set indicator to “0”.
4. M ove the output shaft in and out noting the
amount of end play. Correct end play is between
7 CASE 0.127 to 0.635 mm (0.005 to 0.025 inch).
235 SHAFT, STATOR
• Retain this m easurement for future use.
502 SHAFT, TURBINE RH0112-4L80-E-R1
Figure 13 Front Unit End Play Check Important
During reassembly, Rear End Play Check must

be repeated to verify accuracy o f selective
washer.
REMOVE
O-RING J 37789
FIRST
7 CASE ASSEMBLY, COMPLETE

671 SHAFT & BUSHING ASSEMBLY, OUTPUT RH0114-4L80-E
Figure 15 Rear Unit End Play Check
2 SEAL, O-RING (TURBINE SHAFT/TURBINE HUB)

THICKNESS IDENTIFICATION NOTCH RH0116-4L80-E
(INCH) AND/OR NUMERAL

Figure 17 Oil Pump Removal
.074 - .078 NONE 1
.082 - .086 ON SIDE OF 1 TAB 2
J 37789
.090 - .094 ON SIDE OF 2 TABS 3
.098-.102 ON END OF 1 TAB 4
.106- .110 ON END OF 2 TABS 5
.114- .118 ON END OF 3 TABS 6
RH0115-4L80-E
Figure 16 Output/Case Selective Thrust Washer
PUMP ASSEMBLY
Figures 17 and 18
Tool Required:
J 37789 Pump Rem over
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
washer.
218 WASHER, THRUST SELECTIVE
RH0117-4L80-E
Figure 18 Pump Assem bly and Selective Thrust

Washer
OVERDRIVE UNIT AND FOURTH CLUTCH

ASSEMBLY
Figures 19 and 20
|<~»| Remove or Disconnect
1. Overdrive unit assembly (504) and turbine shaft

(502) by lifting turbine shaft.
2. Recheck Fourth Clutch Bolt (26). Torque should
be 23 N*m m inimum (204 lb. in. minimum).
3. Fourth clutch bolt (26) using 40T torx head
socket.
NOTICE: Discard bolt, do not reuse! Damage
could result to the Fourth Clutch Housing.
4. Fourth clutch assembly complete (529).
502 SHAFT, TURBINE

504 HOUSING ASSEMBLY, 26 BOLT, CASE (4TH CLUTCH)
OVERRUN CLUTCH RH0118-4L80-E 529 HOUSING, 4TH CLUTCH
Figure 19 Removing Overdrive Unit Assembly S H 0119-4L80-E
Figure 20 Removing 4th Clutch Assembly

FORWARD CLUTCH ASSEMBLY DIRECT CLUTCH ASSEMBLY

Figure 21 Figure 22
Tool Required: Tool Required:
J 3 8 3 5 8 -A F o rw a rd C lu tch A ssem b ly J 38733 Direct Clutch Assembly Rem over
Rem over and Installer
|+"»| Remove or Disconnect
|*-»| Remove or Disconnect
1. D irect clutch housing assem bly (623) using
1. Bearing assembly (601). From top o f forward J 38733.
clutch housing. 2. Front band (628).
2. Forward clutch assembly complete (602).
3. Thrust washer (612). This washer may be stuck
to the bottom of the forward clutch assembly or
top of direct clutch housing.
INTERMEDIATE CLUTCH ASSEMBLY

Figure 23
p *| Remove or Disconnect
1. Snap ring (629).
2. Intermediate clutch backing plate (630).
3. Clutch plates (631 and 632), four each.
reconditioned, the center support and bolt must be

replaced to avoid component damage. The service
bolt is coated with zinc chrom ate and is yellow in
color and the production bolt is phosphate coated
and is black in color.
1. Center support bolt (25), using 3/8"-12 pt. head

socket.
NOTICE: Discard bolt, do not reuse! Dam age
could result to the Center Support Housing.
2. Snap ring (633) (tapered).
3. Attach tool J 38868 to main shaft (662).
4. Center support assembly (634-641) and gear unit
assembly (642-672) using tool J 38868.
• Secure tool J 38868 tight to shaft using
wrench.
• Place center support assembly and gear unit
assembly into J 6116-01 fixture.
5. Tool J 38868.
6. Spacer (643).
• Location of thin spacer (643) located at
bottom of case splines.
7. R ear band (657), th ru st w asher (673) and
selective thrust washer (674).
| 9 | Important
• T hrust w ashers (673 and 674) m ay be

attached to the output shaft and gear unit
629 RING, SNAP (INTERMEDIATE CLUTCH RETAINER) assembly or bottom of case.
630 PLATE, INTERMEDIATE CLUTCH BACKING • If rear end play m easurement was incorrect,
631 PLATE ASSEMBLY, INTERMEDIATE CLUTCH
632 PLATE, INTERMEDIATE CLUTCH RH0122-4L80-E
use rem oved washer and chart to select new
washer.
Figure 23 Removing Intermediate Clutch Plates
CENTER SUPPORT AND GEAR UNIT

ASSEMBLY AND REAR BAND
Tools Required:
J 6116-01 Gear Holding Fixture
J 21364-A Adapter
J 38868 G ear A ssem b ly R em o v er and
Installer
J 39919-1 Reamer
J 6125-1B Slide Ham mer
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
640-672
R 73
643 SPACER, SUPPORT TO CASE

657 BAND ASSEMBLY, REAR BRAKE
R H0125-4L80-E
Figure 26 Removing Rear Band and Selective Thrust

Washer
COMPONENT REPAIR AND

TRANSMISSION REASSEMBLY
The assembly of some components will require use of
an a s se m b ly lu b e. It is re c o m m e n d e d th a t
TRANSJEL™ J 36850 or the equivalent of petroleum
jelly be used during assembly.
NOTICE: Do not use any type of grease to retain
parts during assembly o f this unit. Greases other
than the recommended assembly lube will change
633 RING, SNAP CENTER SUPPORT/CASE tra n sm issio n flu id c h a ra c te ristic s and cau se
640 SUPPORT AND RACE ASSEMBLY, CENTER undesirable shift conditions and/or filter clogging.
642-672 CENTER SUPPORT AND GEAR UNIT ASSEMBLY
673 WASHER, THRUST
SH 0124-4L80-E
Figure 25 Removing Center Support and Gear Unit

Assem bly
TRANSMISSION CASE 6. Two cooler connectors (8) for:

Figure 27 • Damage.
• Proper torque 35 N*m (26 lb. ft.).
[y | Inspect
7. Intermediate clutch plate lugs for:
1. Case (7) for: • Damage.
• Cracks. 8. Snap ring grooves for:
• Porosity. • Damage.
• Connected passages. 9. Case center support bolt hole for:
• Scored bushing (78). • Damage.
• Excess gasket material left on surfaces. 10. Speed sensors and brackets.
2. Case extension (19) for: 11. Vent pipe (9).
• Cracks. 12. PW M solenoid screen (75).
• Porosity. 13. Rear lube seal (13) and snap ring (14).
• Scored bushing (77). • Replace rear lube seal (13) with J 38693 if
necessary.
3. All threaded holes for:
14. M anual shaft seal (707).
• Damage.
- Heli-coil to repair damage. py| Clean
4. Air check all fluid passages. • All components
• See Diagnosis Section for fluid passage
identification. [Y ] Important
5. Front and rear servo bores for:
• Use only clean solvent or cleaner. Do not
• Porosity. use dirty cleaner because additional sediment
• Burrs. could damage transmission.
• Damage.
7 CASE ASSEMBLY, COMPLETE 19 EXTENSION ASSEMBLY, CASE

8 CONNECTOR, INVERTED FLARED TUBE 20 HELIX SEAL ASSEMBLY, CASE EXTENSION
9 PIPE, VENT 21 BOLT, HEX HD - M10 X 1.5 X 30.0
10 SCREW, NAMEPLATE 75 SCREEN, PWM SOLENOID
11 NAMEPLATE 77 BUSHING, CASE EXTENSION
12 CUP, ORIFICE W/SEAL/PLUG-REAR LUBE (4WD) 78 BUSHING, TRANSMISSION CASE
13 SEAL ASSEMBLY, REAR LUBE 79 PLUG, DIRECT OIL GAL - .25 DIA. CUP
14 RING, SNAP SEAL RETAINER 707 SEAL ASSEMBLY, MANUAL SHIFT SHAFT
15 SEAL, EXTENSION TO CASE
S H 0126-4L80-E
Figure 27 Case Assem bly and Extension Assem bly

FOR MODELS
EQUIPPED WITHOUT
NSBU SWITCH
708 SHAFT, MANUAL
SH 0110-4L80-E
Figure 28 Parking Lock and Actuator Assembly
PARKING LOCK PAWL AND ACTUATOR Install or Connect

ASSEMBLY □
Figure 28
NOTICE: Do not apply excessive force, prying,
or hamm ering to any parking mechanism parts,
jF®l Inspect doing so could cause parking system failure.
1. Parking pawl (703) for: 1. Pawl shaft (702).
• Cracks. 2. Parking pawl (703).
• Burrs. 3. Plug (701) (using 5/16 rod) with loctite.
• Damage. 4. Retainer (704).
2. Parking pawl shaft (702) for: 5. Pawl return spring (705).
• Damage. 6. Detent lever (711) to actuator assembly (710).
7. A ctuator assem bly (710) over parking paw l
• Freeness of fit.
(703).
3. Parking pawl return spring (705) for:
8. Seal (707) and manual shaft (708).
• Distortion.
9. Nut (712) using 15 mm wrench on shaft (708).
• Damage.
4. Detent lever (711) and actuator (710) for: Tighten
• Cracks. • Nut (712) to 24 N-m (18 lb. ft.)
• Damage.
10. Manual shaft retaining pin (709).
5. Manual shaft (708) for:
11. Parking lock bracket (713) with two bolts (714).
• Damaged flats or threads.
• Wear. Q Tighten
6. M anual shaft retaining pin (709) for: • Bolts (714) to 24 N*m (18 lb. ft.)
• Tightness.
REAR BAND AND SELECTIVE THRUST WASHER CENTER SUPPORT AND GEAR UNIT ASSEMBLY
Figure 29 Figures 30 and 31
[y | Inspect Tools Required:

J 38868 Gear Unit Assembly Rem over and
• Rear band (657) and selective thrust washer (674) Installer
for:
J 23093 Center Support Locating Tool
- Wear.
- Damage. J 8001 Dial Indicator Set
J 6125-IB Slide Ham mer
|-»<-| Install or Connect J 28585 Snap Ring Tool
1. Selective thrust washer (674) determined by Rear
End Play M easurem ent during disassem bly. |<$»| Disassemble
S m o o th sid e fa c in g up. R e ta in w ith
TRANSJEL™ J 36850 or equivalent. 1. Center support (640) and thrust washer (642).
2. Rear band (657). 2. Sun gear shaft (649).
• M ake sure band tab lines up with servo pin 3. Reaction drum and carrier assembly (651).
hole. 4. Thrust bearing (647), races (646 and 648) and
sun gear (650).
5. Front internal reaction carrier washer (659).
6. Snap ring (670), output shaft (671).
7. Thrust bearing (647) and races (648 and 669).
8. Rear internal gear (666) and main shaft (662).
9. Snap ring (670) from main shaft (662).
10. M ain shaft (662).
11. Thrust bearing (664) and races (663 and 665).
|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.
Figure 29 Rear Band and Selective Thrust Washer

530 PLUG, ORIFICE CENTER SUPPORT

634 RING, SNAP INTERMEDIATE CLUTCH
635 SPRING AND RETAINER ASM., INTERMEDIATE CLUTCH
636 PISTON, INTERMEDIATE CLUTCH
637 SEAL, INTERMEDIATE CLUTCH (INNER)
638 SEAL, INTERMEDIATE CLUTCH (OUTER)
639 RING, OIL SEAL
640 SUPPORT AND RACE ASSEMBLY, CENTER
642 WASHER, THRUST SUPPORT/REACTION DRUM
643 SPACER, SUPPORT TO CASE
644 ROLLER CLUTCH ASSEMBLY
645 RING, REACTION DRUM SPACER
646 RACE, THRUST BEARING TO CENTER SUPPORT
647 BEARING, NEEDLE THRUST
648 RACE, THRUST BEARING
649 SHAFT ASSEMBLY, SUN GEAR
650 GEAR, SUN
651 DRUM AND CARRIER ASSEMBLY, REACTION
652 WASHER, PINION THRUST (BRONZE)
653 WASHER, PINION THRUST (STEEL)
654 ROLLER, NEEDLE BEARING
655 PINION, PLANET
656 PIN, PLANET PINION
657 BAND ASSEMBLY, REAR BRAKE
659 WASHER, FRONT INTERNAL/REACTION CARRIER
660 RING, OUTPUT SPEED SENSOR
661 CARRIER ASSEMBLY, OUTPUT
662 SHAFT, TRANSMISSION MAIN
663 RACE, THRUST BEARING TO SUN GEAR
664 BEARING, NEEDLE THRUST RR INTERNAL GEAR
665 RACE, THRUST BEARING TO RR INTERNAL GEAR
666 GEAR, REAR INTERNAL
669 RACE, THRUST BEARING TO OUTPUT SHAFT
670 RING, SNAP MAINSHAFT INTERNAL GEAR
671 SHAFT AND BUSHING ASSEMBLY, OUTPUT
672 RING, SNAP (OUTPUT SHAFT/ FRONT INTERNAL GEAR)
673 WASHER, THRUST
675 SEAL, O-RING OUTPUT SHAFT
676 BUSHING, SUN GEAR SHAFT
677 BUSHING, OUTPUT SHAFT
678 BUSHING
681 BUSHING, REACTION DRUM
682 SLEEVE, TRANS. OUTPUT SHAFT YOKE SEAL
683 SEAL, OUTPUT SHAFT
657
S H 0128-4L80-E
Figure 30 Center Support and Gear Unit Assem bly

• 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
Figure 32 M easuring Reaction Carrier Pinion End Play

Center Support Assembly

Tools Required:
J 6116-01 Rear Gear Assembly Holding
Fixture
J 21363 Intermediate Clutch Inner Seal
Protector
J 23327 Clutch Spring Com pressor
J 38734 Intermediate Clutch Piston
Com pressor Adapter
J 38735-1 Solid Seal Installer
J 38735-2 Seal Sizer
J 38735-3 Seal Pusher
|+-»| Remove or Disconnect

530 PLUG, ORIFICE CENTER SUPPORT
Figure 33 633 RING, SNAP CENTER SUPPORT/CASE
1. Press in on spring retainer (635) and remove 635 SPRING AND RETAINER ASM., INTERMEDIATE CLUTCH
snap ring (634) using J 38734 Adapter. 636 PISTON, INTERMEDIATE CLUTCH
2. Spring and retainer assembly (635). 637 SEAL, INTERMEDIATE CLUTCH (INNER)
3. Clutch piston (636). 639 RING, OIL SEAL
4. Inner seal (637) and outer seal (638) from clutch 640 SUPPORT AND RACE ASSEMBLY, CENTER
piston (636). 642 WASHER, THRUST SUPPORT/REACTION DRUM
RH0131-4L.80-E
| 9 | Important Figure 33 Center Support and Intermediate Clutch

Piston
• Do not remove three bolts holding roller clutch
race to center support (640). A new center support
comes with a race assembly (640) and bolt (25)
should be used for any overhaul.
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).
I? ) Assemble
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
Figure 36 Center Support and Reaction Carrier

J 21363 Assembly
Gear Unit Assembly

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).
647 BEARING, NEEDLE THRUST

648 RACE, THRUST BEARING
662 SHAFT, TRANSMISSION MAIN
663 RACE, THRUST BEARING TO SUN GEAR
664 BEARING, NEEDLE THRUST RR INTERNAL GEAR
665 RACE, THRUST BEARING TO RR INTERNAL GEAR
666 GEAR, REAR INTERNAL
669 RACE, THRUST BEARING TO OUTPUT SHAFT
670 RING, SNAP MAINSHAFT INTERNAL GEAR
671 SHAFT AND BUSHING ASSEMBLY, OUTPUT
672 RING, SNAP (OUTPUT SHAFT/ FRONT INTERNAL
GEAR)
673 WASHER, THRUST
675 SEAL, O-RING OUTPUT SHAFT R H 0 1 3 5 -4 L 8 0 -E
Figure 37 Assembling Output Shaft and Rear Internal

Gear
7. Snap ring (672) in groove o f output carrier

assembly (661).
8. Thrust washer (673) onto output shaft (671).
9. O-ring seal (675). (Some models.)
10. Thrust washer (659) onto output carrier assembly
(6 6 1 ) w ith ta b s in p o c k e ts . R e ta in w ith
TRANSJEL™ J 36850 or equivalent. 647 BEARING, NEEDLE THRUST
11. Reaction drum and carrier assembly (651) into 648 RACE, THRUST BEARING
649 SHAFT ASSEMBLY, SUN GEAR
output carrier (661).
650 GEAR, SUN
• L u b ric a te p in io n g e a rs (6 5 5 ) w ith 651 DRUM AND CARRIER ASSEMBLY, REACTION
DEXRON®-III transmission fluid. 659 WASHER, FRONT INTERNAL/REACTION CARRIER
660 RING, OUTPUT SPEED SENSOR
661 CARRIER ASSEMBLY OUTPUT
SH 0136-4L80-E
Figure 38 Assem bling O utput and Reaction Carrier

J 39919-2 Gage to make sure the bolt hole is not

oversized. The new, larger service bolt must be
633 used with the reconditioned center support to avoid
component damage. If the center support has been
previously reconditioned, the center support and
bolt must be replaced to avoid com ponent damage.
The service bolt is coated with zinc chromate and
is yellow in color and the production bolt is
640 phosphate coated and is black in color.
18. New or reconditioned center support (640) into
reaction carrier (651).
|T) Important
• To verify correct assembly, hold reaction carrier
643
(651) stationary. Center support (640) should turn
counterclockwise only.
646
642
RING, SNAP CENTER SUPPORT/CASE

SUPPORT AND RACE ASSEMBLY, CENTER
WASHER, THRUST SUPPORT/REACTION DRUM
SPACER, SUPPORT TO CASE
ROLLER CLUTCH ASSEMBLY
RING, REACTION DRUM SPACER
RACE, THRUST BEARING TO CENTER SUPPORT
SHAFT ASSEMBLY, SUN GEAR
DRUM AND CARRIER ASSEMBLY, REACTION
RING, OUTPUT SPEED SENSOR
RH0137-4L80-E
Figure 39 Installing Spacer Ring and Roller Clutch

Assembly
12. Sun gear (650) (chamfered inner diam eter first) 635 SPRING AND RETAINER ASM., INTERMEDIATE CLUTCH
into reaction drum and carrier assembly (651). 636 PISTON, INTERMEDIATE CLUTCH
13. Sun gear shaft (649), long splined end into sun 637 SEAL, INTERMEDIATE CLUTCH (INNER)
gear (650).
639 RING, OIL SEAL r h o i 34.-4. i r o - f
14. Longer lipped race (648) on sun gear shaft (649)
with lip up. Figure 40 Center Support and Reaction Carrier
15. Needle thrust bearing assembly (647), on long Assembly
lipped race (648).
16. With center support assembly (640) on bench, 19. Spacer (643) to the bottom of case splines. Leave
a tta c h ra c e (6 4 6 ) o n to re a r hub w ith opening of snap ring at nine o ’clock position.
TRANSJEL™ J 36850 or equivalent. • Third snap ring groove down.
17. Thrust washer (642) in recess of center support 20. J 38868 to main shaft (662).
(640). 21. W ith transmission in a vertical position, align
bolt hole in center support (640) with hole in
NOTICE: The original center support may be case (7) and carefully lower gear unit/center
reconditioned ONE TIM E by using J 39919-1 support assembly into case using J 38868.
Reamer. M easure the center support bolt hole with
22. Beveled snap ring (633). Flat side down using

J 28585.
• The end gap should be located at the nine
o ’clock position with the beveled edge of
the snap ring facing up.
LOCATION
OF (643)
SNAP RING
RH0177-4L80-E
Figure 41 Location of Snap Ring (643)
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
Figure 42 Installing Center Support and Gear Unit

Assem bly
REAR UNIT END PLAY CHECK Center Support Bolt

Figures 43 and 44 p 7 | Install or Connect
Measure Figure 45
Tool Required: 1. Locate J 23093 into the center support (640)
J 8001 Dial Indicator Set direct clutch passage through case (7). Apply
pressure on J 23093, seating the center support
1. Attach J 8001 rod to one of the bolt holes at the splines counterclockwise against the case splines.
end o f the transmission case (7). (Push tool toward rear servo bore.)
2. M ount J 8001 on the rod and index it to end of 2. New case to center support bolt (25).
the output shaft (671). Set indicator to “0.” • Assure the bolt head (25) is seated to the
3. M ove the output shaft in and out noting the bottom of the case (7).
am ount o f end play. Correct end play is between
0.127 to 0.635 mm (0.005 to 0.025 inch). [$Q Tighten
• New center support bolt (25) to 43 N*m
(32 lb. ft.) using 3/8 inch -12 pt. socket.
| 9 | Important
• DO NOT OVERTORQUE!
THICKNESS IDENTIFICATION NOTCH

(INCH) AND/OR NUMERAL
.074 - .078 NONE 1
.082 - .086 ON SIDE OF 1 TAB 2
.090 - .094 ON SIDE OF 2 TABS 3
.098- .102 ON END OF 1 TAB 4
.106- .110 ON END OF 2 TABS 5
.114- .118 ON END OF 3 TABS 6
R H0115-4L80-E
Figure 44 Output/Case Selective Thrust Washer (674)
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
Figure 45 Center Support A lignm ent Tool

DIRECT CLUTCH ASSEMBLY

Tools Required:
J 21362-1 Seal Protector (inner)
J 23327-1 Spring Compressor
J 25018-A Adapter M echanical Press
J 38695 Spiral Snap Ring Installer
J 38732-1 Seal Protector (outer)
J 24396 Intermediate Clutch Pack Alignment
J 38733 Direct Clutch Assembly Remover
and Installer
ff] Important
• If spiral snap ring (627) is removed, a new snap

ring (627) m ust be used.
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.
[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:
• Distortion.
Assemble
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
Figure 47 Direct Clutch Assem bly and Intermediate

Sprag Assem bly
4. Place snap ring (627) over direct clutch hub,

in s ta ll to o l J 3 8 6 9 5 in hub h o le , ro ta te
counterclockwise while pressing down until snap
ring is in place.
5. Dished plate (609) into direct clutch housing
(623). Inner diam eter dish down.
6. Plate assemblies (611) and steel plates (618)
.092 inch thickness.
• Alternate plates, starting with steel plate first.
7. Direct clutch backing plate (617) and snap ring
(616).
Q —
GROOVES
UP 626
Figure 48 Installing Direct Clutch Piston
625
624
623

625 RACE, INTERMEDIATE CLUTCH (OUTER)
626 RETAINER, INTERMEDIATE CLUTCH
627 RING, EXTERNAL LOCKING
R H0141-4L80-E-R1
Install or Connect
E
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).
5. Remove direct clutch assembly (623).

HYDRA-MATIC 4L80-E
CLUTCH PLATE APPLICATION CHART
DIRECT CLUTCH
NO. OF NO. OF NO. OF PISTON 623

FLAT STEEL DISHED COMPOSITION TRAVEL
MODELS PLATES PLATES PLATES CHECK
2.32MM 1.37MM 2.03MM

THICKNESS
(.0915") (.054") (.080") 3.07-4.27MM
(0.121-0.186")
ALL MODELS 5 1 5
RH0143-4L80-E
640
Figure 52 Direct Clutch Plate Chart
624 626 A DIRECT CLUTCH FLUID PASSAGE

B REVERSE CLUTCH FLUID PASSAGE
640 SUPPORT & RACE ASSEMBLY, CENTER RH0145-4L80-E
Figure 54 Air Checking Direct Clutch
INTERMEDIATE CLUTCH ASSEMBLY AND

FRONT BAND
Inspect
616 617 619 607 608 605 622 611 618
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
Assemble
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.
1. Place direct clutch assem bly (623) on center Measure

support (640) for air check operation.
• End play check for interm ediate clutch
2 . Place indicator onto piston (619). piston travel. 1.02 to 2.72 mm (0.040 to
3. Air applied to reverse passage will escape from 0.107 inch). Using feeler gage betw een
direct passage. This condition is normal. Apply backing plate (630) and snap ring (629).
80 psi of air pressure to direct passage to actuate
piston and move clutch plates. 4. Front band (628).
4. Piston travel should be 3.07 to 4.72 mm (0.121 • Check for proper position and freedom of
to 0.186 inch). movement.
HYDRA-MATIC 4L80-E
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
Figure 56 Intermediate Clutch Plate Chart
5. Align clutch plates (631 and 632) with J 24396.

Leave tool in place.
6. Apply air through center support bolt hole to
engage intermediate clutch.
7. Remove tool J 24396.
8. Continue applying air to hold clutch plates in
place.
9. Direct clutch assembly into case with J 38733.
628 BAND ASSEMBLY, FRONT

629 RING, SNAP (INTERMEDIATE CLUTCH RETAINER)
630 PLATE, INTERMEDIATE CLUTCH BACKING
631 PLATE ASSEMBLY, INTERMEDIATE CLUTCH
632 PLATE, INTERMEDIATE CLUTCH
RH0181-4L80-E
Figure 55 Installing Intermediate Clutch Plates and

Front Band
FORWARD CLUTCH ASSEMBLY |ig | Clean

• All components.
Tools Required:
J 23327-1 Spring Com pressor |^ | Inspect
J 38732-1 Seal Protector (outer) Figure 59
J 21362-1 Seal Protector (inner)
J 8001 Dial Indicator Set • Burned.
J 2 5 0 18-A Adapter M echanical Press • Scoring.
|+$»| Disassemble • Flaking.
• Pitting.
Figures 58 and 59
• Wear.
1. Snap ring (616) and direct clutch driving hub
2. Spring and retainer assem bly (607) for:
(615) from forward clutch housing (602).
2. Forward clutch hub (613).
• Distortion.
3. Thrust washers (614 and 612).
4. Clutch plates (610 and 611). 3. Clutch hubs (613 and 615) for:
5. Dished plate (609). • Spline wear.
6. Snap ring (608), spring and retainer assembly • Open lubrication holes.
(607) using J 23327-1. • Dam aged thrust faces (613).
7. Piston (606), and seals (604 and 605). • Clutch surface (615).
8. Seal (603) from forward clutch housing (602). 4. Piston (606) for:
• Cracks.
5. Seals (603, 604 and 605) for:
• Cuts.
• Tears.
• Nicks.
6. Forward clutch housing (602) for:
• Wear.
• Open lubrication holes.
• Damaged thrust faces.
• Free operation of checkball.
Figure 58 Removing Forward Clutch Piston Release

Springs
Assemble
Figures 58,59, 60, 61 and 62

1. Lubricate new inner seal (605) and outer seal
(604) with DEXRON®-III transm ission fluid.
L u b ric a te seal g ro o v es w ith TRANSJEL™
J 36850 or equivalent.
2. Seals (604) and (605) on piston (606) with lips
facing down towards housing.
3. Lubricate center housing seal (603) and groove.
4. Center housing seal (603) onto forward clutch
housing (602) with lip facing up.
5. J 21362-1 over clutch hub.
6. Piston (606) inside J 38732 and insert assem bly
into housing (602) rotating slightly until seated.
7. R e ta in e r and sp rin g a ssem b ly (607) w ith
J 23327-1.
8. Snap ring (608).
J 21362-1
J 38732-1
602 HOUSING ASSEMBLY, FORWARD CLUTCH

606 PISTON, FORWARD CLUTCH
RH0148-4L80-E
Figure 60 Installing Forward Clutch Piston
9. Dished clutch plate (609). Inner diam eter dish

down.
601 BEARING ASM., THRUST CARRIER/FORWARD CLUTCH 10. Steel plates (610) .078 inch thickness and plate
602 HOUSING ASSEMBLY, FORWARD CLUTCH assemblies (611). Starting with steel plate first.
604 SEAL, CLUTCH (OUTER) 11. Direct clutch hub (615) in forward clutch housing
605 SEAL, CLUTCH (INNER) (602).
606 PISTON, FORWARD CLUTCH 12. Snap ring (616).
608 RING, SNAP 13. Install forward clutch assembly onto turbine shaft
609 PLATE, CLUTCH (.054 DISHED) (502).
610 PLATE, CLUTCH (.0775 FLAT)
611 PLATE ASSEMBLY, CLUTCH
612 WASHER, THRUST CLUTCH HUB HOUSING
[|f| Measure
613 HUB, FORWARD CLUTCH DRIVEN
614 WASHER, THRUST FORWARD CLUTCH
615 HUB, DIRECT CLUTCH DRIVING • M easure piston travel with J 8001 dial indicator
616 RING, SNAP (6.24 O.D. X .062) set by applying air to forward clutch passage.
685 SLEEVE AND SEAL ASSEMBLY
RH0147-4L80-E
Figure 59 Forward Clutch Assem bly

• Piston travel is 3.07-4.72 mm (0.121-0.186 inch).

• Remove J 8001, snap ring (616) and hub (615).
NOTICE: If excessive leakage from turbine shaft

(502) or seals (503) then use reconditioned shaft.
14. Bronze thrust washer (612) on inside o f hub

(613). Retain with TRANSJEL™ J 36850 or
equivalent.
15. Thrust washer (614) on outside of forward clutch
hub (613).
16. Forward clutch hub (613) in clutch housing (602).
| 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).
Figure 61 Installing Forward Clutch Piston Release

Springs
HYDRA-MATIC 4L80-E
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
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
Figure 63 Checking Forward Clutch Piston Travel

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).
601 BEARING ASM., THRUST CARRIER/FORWARD CLUTCH

RH0120-4L80-E
Figure 64 Installing Forward Clutch Assembly
FOURTH CLUTCH ASSEMBLY

Tools Required:
J 38731 Fourth Clutch Seal Protectors and
Base
J 38882 A d apter F o u rth C lutch Spring 523 RING, SNAP (4TH CLUTCH)
Com pressor 524 PLATE, 4TH CLUTCH BACKING
525 PLATE ASSEMBLY, 4TH CLUTCH
J 23327-1 Spring Com pressor 526 PLATE, 4TH CLUTCH
527 SEAL, 4TH CLUTCH (INNER)
528 PISTON, 4TH CLUTCH
529 HOUSING, 4TH CLUTCH
530 PLUG, ORIFICE
531 SEAL, 4TH CLUTCH (OUTER)
532 SPRING GUIDE AND RETAINER ASSEMBLY, 4TH
CLUTCH
533 RING, SNAP (SPRING AND RETAINER ASSEMBLY 4TH
CLUTCH PISTON) R H0151-4L80-E
Figure 65 Fourth Clutch Components

13. Backing plate (524) flat side down, notch location

same as steel plates and snap ring (523).
| V | Important
• Insure snap ring (523) is properly seated in
groove.
[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)
index notch opposite 4th clutch bolt hole. RH0183-4L80-E-R1
Figure 67 Installing Fourth Clutch Bolt

523 524
523 RING, SNAP (4TH CLUTCH)

524 PLATE, 4TH CLUTCH BACKING
526 PLATE, 4TH CLUTCH
532 SPRING GUIDE AND RETAINER ASSEMBLY,
4TH CLUTCH
533 RING, SNAP (SPRING AND RETAINER ASSEMBLY
4TH CLUTCH PISTON)
RH0153-4L80-E-R1
Figure 68 Fourth Clutch Assembly Figure 69 Overdrive Unit Assembly
OVERDRIVE GEAR UNIT Overrun Clutch Assembly

Figure 69 Figures 70 through 73
|<$»| Disassemble Tools Required:
J 38729 Piston Seal Protector
1. Snap ring (522).
2. Turbine shaft (502). J 8001 Dial Indicator Set
3. Overrun carrier assembly (514) from housing J 23327-1 Clutch Piston Com pressor
(504). J 38734 Adapter
[<$»| 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).
2. Spring and retainer assembly (506) for:

• Distortion.
3. Piston (505) for:
• Cracks.
• Cut seal.
4. Housing (504) for:
• Wear.
• Open lube holes.
• Dam aged thrust faces.
|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).
505 PISTON ASSEMBLY, OVERRUN CLUTCH

507 RING, SNAP RETAINER
508 PLATE, OVERRUN CLUTCH
509 PLATE ASSEMBLY, OVERRUN CLUTCH
510 PLATE, OVERRUN CLUTCH BACKING
511 RING, SNAP RH0155-4L80-E
Figure 70 Overrun Clutch Assembly
p y l Clean
• All components.
• Piston (505) should not be cleaned with solvent.
[ffi Inspect
• Burning.
• Scoring.
• Flaking.
• Pitting.
• Wear.
Measure Overdrive Carrier Assembly

Figure 72 Figure 74
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
511 RING, SNAP R H0157-4L80-E
Figure 72 Measuring Overrun Clutch Piston Travel
|«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.
2. Four pinion pins (519) from carrier (514).
506 SPRING AND RETAINER ASSEMBLY 3. Pinions (518), thrust washers (515 and 516) and
507 RING, SNAP RETAINER roller needle bearings (517).
510 PLATE, OVERRUN CLUTCH BACKING |g | Clean
• All components.
Figure 73 Overrun Clutch Assem bly
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
518 PINION, OVERDRIVE PLANET
519 PIN, OVERDRIVE PINION
520 RETAINER, PINION PIN
Figure 76 Overdrive Carrier Assembly
513 BEARING ASSEMBLY, THRUST CARRIER/

OVERRUN CLUTCH
Figure 75 Overdrive Carrier Assembly

TURBINE SHAFT AND OVERDRIVE CARRIER 3. Remove installer.

ASSEMBLY 4. Place sizer J 38736-3 and J 38736-4 over shaft
Figures 77 through 80 to size seals in place.
Tools Required: [T l Important
J 38736 Turbine Shaft Seal Installation Kit • Be sure to use small chamfer end of sizer to
Seal Sizer (2 different sizes) do the lower ring. Then use larger chamfered
end to size all other seals.
Seal Installer (2 different sizes)
5. Remove sizer.
Seal Pusher (2 different sizes)
6. Always start with low er seal first and work
|y | Inspect towards top.
7. Repeat procedure with different size set of tools
Figure 77 for opposite end.
1. Seals (501 and 503). 8. Overdrive carrier assembly (514) into housing
2. Checkball (534) on end of shaft (502). assembly (504).
3. Splines on shaft (502). • DO NOT DAM AGE SEALS.
• Rotate overdrive carrier assem bly while
El Disassemble lining up overrun clutches.
• Turbine shaft seals (501 and 503). 9. Turbine shaft (502) through housing (504) until
splines show through.
E3 Assemble 10. Snap ring (522).
Figures 78 and 79 11. B earing assem bly (601) with TRANSJEL™
J 36850 or equivalent, onto forw ard clutch
1. Place seal installers J 38736-1 and J 38736-2 onto housing (602). Silver side up.
shaft.
2. Push seals (501 and 503) over and down the
installer until they are in place, using pusher
tool. One at a time.
501 RING, OIL SEAL (TURBINE SHAFT/STATOR HSG.)

502 SHAFT, TURBINE
503 RING, OIL SEAL (TURBINE SHAFT/FORWARD HSG.)
511 RING, SNAP
512
513
ROLLER CLUTCH ASSEMBLY, OVERDRIVE
BEARING ASSEMBLY, THRUST CARRIER/ OVERRUN
CLUTCH
©
520 RETAINER, PINION PIN 520
521 RING, SNAP •517
522 RING, SNAP (TURBINE SHAFT/CARRIER) 521-—
537 BALL, CHECK _ 518
522 ^ ---- 516
X111 ----
T -519
515
RH0162-4L80-E
Figure 77 Overdrive/Overrun Clutch Assem bly


Figure 80
1. Complete assembly into case.
9| Important
• Be sure assembly is fully engaged and is at

the level of the 4th clutch housing. Using
selective thrust washer (218) onto top of
overrun housing and straight edge to pump
to cage surface. The two surfaces should be
flush.
FOURTH CLUTCH PLATES

|-»<-| Install or Connect
Figures 81 and 82
1. Fourth clutch plates (525 and 526) starting with
steel first into 4th clu tch h o u sin g around
overdrive carrier assembly.
NOTE: Install steel plates with the narrow tang
(“V” notch) at the one o ’clock position in the
601 BEARING ASM., THRUST CARRIER/FORWARD CLUTCH housing.
RH0164-4L80-E
2. Backing plate (524) with wide surface against
Figure 79 Installing Bearing Assem bly the composition plate (525).
3. Fourth clutch snap ring (523) into the fourth
clutch housing (529).
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.
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
Figure 83
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.
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.
5 SEAL, OIL PUMP TO CASE

201 HELIX SEAL ASSEMBLY, PUMP BODY
203 BODY, OIL PUMP 221 RING, SNAP
204 GEAR, PUMP DRIVEN 223 VALVE, TCC
205 GEAR, PUMP DRIVE 224 SPRING, TCC VALVE
206 COVER, PUMP 225 PLUG, TCC VALVE BORE
207 PLUG, CUP (5) 226 RING, RETAINER {REV. BOOST VALVE BUSHING)
208 PLUG, ORIFICED CUP (1) 227 BUSHING, REVERSE BOOST VALVE
209 PLUG, CUP (2) 228 VALVE, REVERSE BOOST
210 PLUG, ORIFICED CUP (1) 229 RETAINER, PRESSURE REGULATOR SPRING
211 PIN, COILED SPRING (3) 230 SPRING, PRESSURE REGULATOR
212 PLUG, CONVERTER LIMIT VALVE BORE 231 VALVE, PRESSURE REGULATOR
213 SPRING, CONVERTER LIMIT VALVE 232 PLUG, VALVE BORE
214 VALVE, CONVERTER LIMIT 233 BUSHING, STATOR SHAFT (FRONT)
215 SLEEVE, SPRING RETAINER 234 BUSHING, STATOR SHAFT (REAR)
216 SPRING, TCC ENABLE VALVE 235 SHAFT, STATOR
217 VALVE, TCC ENABLE 236 PLUG, ORIFICED CUP (1)
218 WASHER, THRUST SELECTIVE 237 PLUG, ORIFICED CUP (1)
219 RING, OIL SEAL 238 SPRING, ISOLATOR PRESSURE REGULATOR
220 BOLT, M 8 X 1.25 X 40 (5) 239 SHIELD, VENT
SH0165-4L80-E
Figure 83 Pump Assem bly

Pump Cover • Check pump body face with straight edge to

Figure 83 insure flatness.
[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).
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.).
12. J 21368 alignm ent band on pum p assem bly.

J 25025-1 Guide pins in bolt holes.
[Y] Important
The outside diam eter of the pum p body and

cover must be properly aligned by tightening
the alignment band. This ensures that the
pum p w ill slid e into the m atin g case
diameter.
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
206 COVER, PUMP

239 SHIELD, VENT
SH0167-4L80-E 219 RING, OIL SEAL
220 BOLT, M8 X 1.25 X 40 (5) RH0168-4L80-E-R1
Figure 85 TCC Enable Valve Spring Rod and Vent
Shield Location Figure 86 Assem bling Pump Body and Pump Cover
J 25025-1

RH0187-4L80-E
Figure 87 Installing Gasket, Pump Cover to Case
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
• 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
• If end play procedures are not closely adhered

to, incorrect shim thickness will be selected
r e s u ltin g in s e v e re d a m a g e to in te rn a l
transm ission components.
Figure 88 Installing Pump Seal

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
1. New seal (57) onto piston (58).

2. Front servo piston spring (60) and retainer (59).
3. Ring (56), piston pin (55) and piston (57).
E3 Install or Connect
• Front servo assembly into case (7).
- M ake certain tapered end of piston pin (55)
contacts band.
Figure 90 Front Unit End Play Check

REAR SERVO PIN CHECK

Tools Required:
J 21370-10 Gage Pin
J 38737 Servo Pin Checking Tool
[||] Measure
1. Place J 21370-10 in the servo pin bore.

2. Position J 38737 over the bore with the hex nut
facing the parking pawl linkage.
3. Fasten with two servo cover bolts (61).
Tighten
• Bolts (61) to 24 N*m (18 lb. ft.).

4. M ake sure J 21370-10 moves freely in the tool
and pin bore.
5. To determine correct pin length apply 25 lb. ft.
torque to the nut on the gage.
6. For pin selection, see Figure 95.
J 38737
55 PIN, FRONT SERVO PISTON

56 RING, FRONT SERVO SPRING RETAINER
57 RING, OIL SEAL
58 PISTON, FRONT SERVO
60 SPRING, FRONT SERVO PISTON
RH0169-4L80-E-R1 RH0106-4L80-E
Figure 92 Front Servo Assembly Figure 93 Installing Servo Pin Gage
J 21370-10
R H 0107-4L80-E
Figure 94 Gage Pin

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).
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.
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.
CONTROL VALVE ASSEMBLY/ACCUMULATOR

HOUSING
NOTICE: T he use o f a h o n in g sto n e, fin e
sandpaper or crocus cloth is not recom mended for
servicing stuck valves. All valve lands have sharply
m achined corners that are necessary for cleaning
the bore. If these corners are rounded, foreign
m aterial could wedge between the valve and the
bore causing the valve to stick. If it is found
necessary to clean a valve, m icro fine lapping
com pound 900 grit (J 38459) or finer should be
used.
Too much lapping of the valve will cause excessive
clearances and increase the chance of a valve not
operating.
Clean
Control valve assembly and accumulator housing
(51) thoroughly in clean solvent.
Air dry.
ACCUMULATOR HOUSING ASSEMBLY

Figures 97 and 98
Disassemble
1. Six bolts (53), using 8 mm socket.
2. Accum ulator housing assembly.
3. Gasket accum ulator housing (47).
4. Spacer plate (46).
5. Gasket (45) valve body spacer.
6. Gasket (48) accum ulator housing to spacer plate.
7. Snap ring (402) from outside housing, pin (408),
snap ring (402), piston (407) and spring (49).
8. 3rd clutch piston (405) and spring (50).
9. Seals (404 and 406).
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
Figure 96 Installing Rear Servo


45 GASKET, VALVE BODY TO SPACER PLATE
46 PLATE, VALVE BODY SPACER
47 GASKET, ACCUMULATOR HSG. TO SPACER PLATE
48 GASKET, SPACER PLATE TO CASE
53 BOLT, ACCUM. HOUSING TO VALVE BODY
SH 0171-4L80-E
Figure 97 Control Valve Assembly/Accumulator

Housing
49 SPRING, 4TH CLUTCH ACCUM. PISTON

50 SPRING, 3RD CLUTCH ACCUM. PISTON
53 BOLT, ACCUM. HOUSING TO VALVE BODY
402 RING, SNAP
404 SEAL, (1.615) SQUARE CUT
405 PISTON, 3RD CLUTCH ACCUMULATOR'
406 SEAL, (.859) SQUARE CUT
407 PISTON, 4TH CLUTCH ACCUMULATOR
408 PIN, 4TH CLUTCH ACCUMULATOR PISTON
RH0172-4L80-E-R1
Figure 98 A ccum ulator Housing Assem bly

|^ | Assemble 4. Valve body casting and accumulator housing for:

• Porosity.
Figure 98
• Cracks.
A ccum ulator housing assem bly com ponents • Interconnected passages.
exactly as shown. Notice the positions of the
valve and pistons. • Damaged machined surfaces.
5. Solenoid, connectors and filter (317).
6. PCS (Pressure Control Solenoid) screen (302).
Assemble
«5n Disassemble
Figure 99
Figure 99
• Control valve assembly components exactly as
• Control valve assembly. shown. Notice the position of the valve lands
A. Position as shown on a clean surface. and bushing passages.
B. Remove blind hole retainer pins with a drill
bit. Control Valve Assembly and Accumulator
CAUTION: Some valves are under Housing
pressure - cover the bores while removing Figures 97 and 100
the retaining pins or personal injury could
result. Tool Required:
Guide Pin J 25025-5
C. Rem ove valve trains, shift solenoids (311
and 313), PCS (320), PW M solenoid (323), hJ h Assemble
PCS screen (302) and shift solenoid filter
(317). 1. Gasket (45) valve body to spacer plate.
D. Valves, springs, bushings and pistons must 2. Spacer plate (46).
be laid out on a clean surface. 3. Gasket (47) accumulator housing to spacer plate.
4. Guide pin J 25025-5 into valve body. Located at
Clean back bolt hole o f detent spring and ro ller
assembly bolt hole.
All valves, springs, bushings, pistons, control
5. Accum ulator housing assem bly (51) onto valve
valve body and accumulator housing in clean
body assembly (44).
solvent.
Dry using compressed air.
6. Six bolts (53) using (8 mm) socket through
accum ulator housing into valve body assembly.
Inspect NOTE: Start accumulator housing bolts finger tight
and work towards opposite end. Tighten sequence
1. All valves, pistons and bushings for: Figure 100.
• Porosity.
• Scoring. Q Tighten
• Nicks. • Bolt (53) to 11 N*m (97 lb. in.)
• Scratches.
7. Remove guide pin J 25025-5.
Pistons for:
• Seal damage.
3. Springs for:
• Damaged or distorted coils.
301 BODY, CONTROL VALVE 318 SLEEVE, LO/REVERSE CHECKBALL

302 SCREEN FILTER, PRESSURE CONTROL SOL FEED 319 VALVE, MANUAL
303 PIN, COILED SPRING 320 PRESSURE CONTROL SOLENOID
304 PLUG, CHECKBALL 321 CLAMP, PRESSURE CONTROL SOL RETAINING
305 BALL, .375 DIA. 322 CLIP, PWM SOLENOID RETAINING
307 SEAL, O-RING 323 SOLENOID ASSEMBLY, PWM
308 VALVE, 3-4 SHIFT 324 VALVE, TCC REGULATOR APPLY
309 SPRING, SHIFT VALVE RETURN (2-3 AND 3-4) 325 SPRING, TCC REGULATOR APPLY VALVE
310 BOLT, SOLENOID (1-2 AND 2-3 SHIFT, PRESSURE 327 SPRING, ACTUATOR FEED LIMIT VALVE
CONTROL SOLENOID) 328 VALVE, ACTUATOR FEED LIMIT
311 2-3 SHIFT SOLENOID AND O-RING ASSEMBLY 329 PLUG, ACCUMULATOR VALVE BORE
312 VALVE, 2-3 SHIFT 330 SPRING, ACCUMULATOR VALVE
313 1-2 SHIFT SOLENOID AND O-RING ASSEMBLY 331 VALVE, ACCUMULATOR
314 VALVE, 1-2 SHIFT 333 PLATE, SPRING RETAINER
315 SPRING, 1-2 SHIFT VALVE RETURN 334 BUSHING, REVERSE BALL VALVE
316 PLUG, SHIFT SOLENOID FEED FILTER 335 BUSHING, 3RD BALL VALVE
317 FILTER, SHIFT SOLENOID FEED
SH 0173-4L80-E
Figure 99 Control Valve Assem bly

2. PW M solenoid screen (75).

3. Gasket (48) spacer plate to case.
4. Com plete valve body assembly (44) onto case
(7). Use J 25025-5 guide pin set.
[~f~| Important
• Attach manual valve to detent lever.

GUIDE
PIN 5. Transmission fluid pressure switch assembly (40)
' ^ " T IO N onto valve body assem bly (44).
6. Spring and roller assembly (41) into place.
7. Three wiring clamps (33), fluid indicator stop
l— I U U
(43) and lube pipe clam p (38).
0 8. Twenty-one bolts (35). Using 10 mm socket.
[—1 b □
0 0 0 o 9. S ix b o lts (7 6 ) u s in g 8 m m s o c k e t in to
1OCD ,— , • transmission fluid pressure switch assembly (40).
,° o CD (
10. Lube pipe (39) long end into case, short end into
valve body.
11. Lube pipe retainer (37) with short bolt (36).
Tighten
• Bolts (35, 36 and 76) to 11 N*m (97 lb. in.).

NOTICE: Torque valve body bolts in a spiral
pattern starting from the center. If bolts are torqued
SH 0174-4L80-E
at random, valve bores may be distorted and inhibit
Figure 100 Torque Sequence and Guide Pin Location valve operation (Figure 103).
12. Attach wiring harness (34) to 5 connectors.
|-n-| Install or Connect • Put large end into case first, pressure switch
Figures 101, 102 and 103 hook up, 1-2 shift solenoid (purple) and 2-3
shift solenoid (tan), PW M (Pulse W idth
1. Install checkballs (54) in proper location into M odulated) solenoid and PCS (Pressure
case fluid passages. Use TRANSJEL™ J 36850 Control Solenoid).
or equivalent to hold in place.
NOTICE: Do not use any type o f grease to retain
parts during assembly of this unit. Greases other
than the recom m ended assembly lube will change
tra n sm issio n flu id c h a ra c te ristic s and cause
undesirable shift conditions and/or filter clogging.
• #2 checkball is used only on RKP, RLP and
ZJP models.
54 BALL, .25 DIA.

#1 OVERRUN CLUTCH 33 CLAMP, ELECTRICAL CABLE
#2 2ND ACCUMULATOR (SOME MODELS) 34 HARNESS ASSEMBLY, ELECTRICAL WIRING
#3 FRONT BAND APPLY 35 BOLT, HEX HD. - M6 X 1.0X55.0
#4 2ND CLUTCH 36 BOLT, M 6X 1.0X35.0 LG V.B. TO C.P.
#5 3RD ACCUMULATOR 37 RETAINER, LUBE PIPE
#6 4TH ACCUMULATOR 38 CLAMP, LUBE PIPE
#8 3RD CLUTCH 39 PIPE, LUBE
#9 REVERSE 40 SWITCH ASM., A/TRANS. FLUID PRESS.
#10 4TH CLUTCH
48 GASKET TO CASE
76 BOLT, SPECIAL
RH0191-4L80-E-R1 SH 0210-4L80-E
Figure 101 Checkball Location Figure 102 Installing Control Valve Assem bly
33 CLAMP, ELECTRICAL CABLE

38 CLAMP, LUBE PIPE
40 SWITCH ASM., A/TRANS. FLUID PRESS.
311 2-3 SHIFT SOLENOID AND O-RING ASSEMBLY
313 1-2 SHIFT SOLENOID AND O-RING ASSEMBLY
323 SOLENOID ASSEMBLY, PWM
RH0192-4L80-E-R1
Figure 103 Bolt Tighten Sequence, Control Valve Assem bly and Switch Assem bly Fluid Pressure
CASE EXTENSION ASSEMBLY

Figure 104
Tools Required:
J 38693 Rear Lube Seal Installer/Case
J 38869 Case Extension Seal Installer
|y | Inspect
1. Bearings (17), bushing (13) and O-ring (15) for:

• Wear.
• Damage.
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.
PAN AND FILTER ASSEMBLY

Figure 105
1. Seal (32) inside of case (7).
2. Filter assembly (31).
3. Bottom pan seal (29).
4. M agnet (30) into bottom pan.
5. Pan (29).
6. Seventeen bolts (27) using 10 mm socket.
• Bolts (27) to 24 N»m (18 lb. ft.)

SPEED SENSOR ASSEMBLIES

Figure 106
[y | Inspect
• Speed Sensor Assemblies (22) for:

- Evidence of damage.
- Fluid seepage.
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.).
27 BOLT, HEX FLANGE HD (PAN TO CASE)

28 PAN, TRANSMISSION OIL
29 SEAL, TRANS. OIL PAN
30 MAGNET, CHIP COLLECTOR
31 FILTER ASSEMBLY, TRANSMISSION OIL
32 SEAL ASSEMBLY, FILTER NECK
22 SENSOR ASM, A/TRANS. INPUT SPD. AND VEH. SPD.
R H0193-4L80-E 23 BOLT, METRIC HEX
S H 0101-4L80-E
Figure 105 Installing Pan and Filter
Figure 106 Speed Sensor Assembly
TORQUE CONVERTER ASSEMBLY

Figure 107
Tools Required:
J 39195 Torque Converter End Play
Checking Tool
J 26900-13 M agnetic Base
J 21369-E Converter Leak Test 1.625 Inch
Plug
J 21366 Converter Holding Strap
The torque converter assem bly (1) m ust be
replaced for any of the following conditions:
Inspect
1. Evidence of damage to the pump assembly.

2. Metal particles are found after flushing the cooler
and cooler lines.
3. External leaks in hub weld area. B Install or Connect
4. Converter pilot is broken, damaged or poor fit • Torque converter (1) with J 21366.
into crankshaft.
5. Converter hub is scored or damaged. NOTICE: Transmission m ust be in the vertical
position.
6. Internal failure to stator.
7. Contamination from engine coolant. - Engage turbine shaft, stator shaft and lugs
8. Excess end play. onto the pump driven gear until converter is
fully engaged.
|^ | Measure
Figure 107 HOLDING FIXTURE

1. Rem ove the T-handle forcing screw from the |* * | Remove or Disconnect
base J 39195.
2. Place J 39195 base into the torque converter. 1. Transmission and holding fixture from J 3289-20.
J 39195 will bottom itself on the face of the 2. Holding fixture J 8763-02 and adapter J 38655
stator. from transmission.
3. Insert the T-handle forcing screw and hand
tighten.
NOTE: This will allow the spline of J 39195 to
grip the spline of the stator for proper measurement.
4. Position J 8001 Dial Indicator as shown in Figure
107. To check end play, push down on J 39195
handles to bottom stator. Now pull up on handles
and check reading. Repeat this procedure a few
times to get an accurate reading. Specs should
be .0 to .024 inch (.0 to .6mm).
The Torque Converter Should Not Be Replaced if:
1. The fluid has an odor, discolored or no evidence
of metal or clutch plate material.
A. Drain out as much fluid as possible
B. Replace the oil filter and pan gasket
C. Fill to proper level (Refer to Section 7A-17A)
2. The converter bolt hole threads are damaged. Figure 108 Transmission Holding Fixture, Base and
Adapter
• Correct with thread insert
Flushing the torque converter is not recommended.
Figure 109 Case and Associated Parts

1 TORQUE CONVERTER ASSEMBLY 44 BODY ASSEMBLY, CONTROL VALVE

2 SEAL, O-RING (TURBINE SHAFT/TURBINE HUB) 45 GASKET, VALVE BODY TO SPACER PLATE
3 BOLT AND SEAL ASSEMBLY, PUMP TO CASE 46 PLATE, VALVE BODY SPACER
4 PUMP ASSEMBLY, COMPLETE 47 GASKET, ACCUMULATOR HSG. TO SPACER PLATE
5 SEAL, OIL PUMP TO CASE 48 GASKET, SPACER PLATE TO CASE
6 GASKET, PUMP COVER TO CASE 49 SPRING, 4TH CLUTCH ACCUM. PISTON
7 CASE ASSEMBLY, COMPLETE 50 SPRING, 3RD CLUTCH ACCUM. PISTON
8 CONNECTOR, INVERTED FLARED TUBE 51 HOUSING, ACCUMULATOR
9 PIPE, VENT 53 BOLT, ACCUM. HOUSING TO VALVE BODY
10 SCREW, NAMEPLATE 54 BALL, .25 DIA.
11 NAMEPLATE 55 PIN, FRONT SERVO PISTON
12 CUP, ORIFICE W/SEAL/PLUG-REAR LUBE (4WD) 56 RING, FRONT SERVO SPRING RETAINER
13 SEAL ASSEMBLY REAR LUBE 57 RING, OIL SEAL
14 RING, SNAP SEAL RETAINER 58 PISTON, FRONT SERVO
15 SEAL, EXTENSION TO CASE 60 SPRING, FRONT SERVO PISTON
16 RING, SNAP INTERNAL 61 BOLT, REAR SERVO COVER
17 BEARING ASSEMBLY, BALL 62 COVER, REAR SERVO
18 SPACER, BEARING 63 GASKET, REAR SERVO COVER
19 EXTENSION ASSEMBLY, CASE 64 CLIP, RETAINING (BOTTOM)
20 HELIX SEAL ASSEMBLY, CASE EXTENSION 65 PISTON, REAR SERVO
21 BOLT, HEX HD - M10 X 1.5 X 30.0 66 RING, OIL SEAL ACCUM PISTON (OUTER)
22 SENSOR ASM, A/TRANS. INPUT SPD. AND VEH. SPD. 67 RING, OIL SEAL ACCUM. PISTON (INNER)
23 BOLT, METRIC HEX 68 PISTON, REAR ACCUMULATOR
24 PLUG, OIL TEST HOLE (HEX HD 1/8 PIPE) 69 SEAL, REVERSE SERVO PISTON
25 BOLT, CASE TO CENTER SUPPORT 70 WASHER, SERVO PISTON
26 BOLT, CASE (4TH CLUTCH) 71 SPRING, REAR SERVO
27 BOLT, HEX FLANGE HD (PAN TO CASE) 72 RETAINER, REAR PISTON SPRING
28 PAN, TRANSMISSION OIL 73 PIN, REAR BAND APPLY (SELECTIVE)
29 SEAL, TRANS. OIL PAN 74 SPRING, REAR ACCUMULATOR
30 MAGNET, CHIP COLLECTOR 75 SCREEN, PWM SOLENOID
31 FILTER ASSEMBLY, TRANSMISSION OIL 76 BOLT, SPECIAL
32 SEAL ASSEMBLY, FILTER NECK 77 BUSHING, CASE EXTENSION
33 CLAMP, ELECTRICAL CABLE 78 BUSHING, TRANSMISSION CASE
34 HARNESS ASSEMBLY, ELECTRICAL WIRING 79 PLUG, DIRECT OIL GAL - .25 DIA. CUP
35 BOLT, HEX HD. - M6 X 1.0 X 55.0 80 PIN, ANCHOR FRONT BAND
36 BOLT, M6 X 1.0 X 35.0 LG V.B. TO C.P. 81 PIN, ANCHOR REAR BAND
37 RETAINER, LUBE PIPE 82 DRAIN PLUG ASM., OIL PAN
38 CLAMP, LUBE PIPE 83 WASHER, TYPE A FLAT GASKET
39 PIPE, LUBE 84 NUT, TRANS. OIL PAN DRAIN PLUG
40 SWITCH ASM., A/TRANS. FLUID PRESS. 85 PAN ASSEMBLY, TRANS. OIL
41 SPRING ASSEMBLY, MANUAL DETENT 86 PLUG, SENSOR BORE
R H0195-4L80-E
Figure 110 Case and Associated Parts - Legend

5 SEAL, OIL PUMP TO CASE

201 HELIX SEAL ASSEMBLY, PUMP BODY
203 BODY, OIL PUMP 221 RING, SNAP
204 GEAR, PUMP DRIVEN 223 VALVE, TCC
205 GEAR, PUMP DRIVE 224 SPRING, TCC VALVE
206 COVER, PUMP 225 PLUG, TCC VALVE BORE
207 PLUG, CUP (5) 226 RING, RETAINER (REV. BOOST VALVE BUSHING)
208 PLUG, ORIFICED CUP (1) 227 BUSHING, REVERSE BOOST VALVE
209 PLUG, CUP (2) 228 VALVE, REVERSE BOOST
210 PLUG, ORIFICED CUP (1) 229 RETAINER, PRESSURE REGULATOR SPRING
211 PIN, COILED SPRING (3) 230 SPRING, PRESSURE REGULATOR
212 PLUG, CONVERTER LIMIT VALVE BORE 231 VALVE, PRESSURE REGULATOR
213 SPRING, CONVERTER LIMIT VALVE 232 PLUG, VALVE BORE
214 VALVE, CONVERTER LIMIT 233 BUSHING, STATOR SHAFT (FRONT)
215 SLEEVE, SPRING RETAINER 234 BUSHING, STATOR SHAFT (REAR)
216 SPRING, TCC ENABLE VALVE 235 SHAFT, STATOR
217 VALVE, TCC ENABLE 236 PLUG, ORIFICED CUP (1)
218 WASHER, THRUST SELECTIVE 237 PLUG, ORIFICED CUP (1)
219 RING, OIL SEAL 238 SPRING, ISOLATOR PRESSURE REGULATOR
220 BOLT, M8 X 1.25 X 40 (5) 239 SHIELD, VENT
SH0165-4L80-E
Figure 111 Oil Pump Assem bly

301 BODY, CONTROL VALVE 318 SLEEVE, LO/REVERSE CHECKBALL

302 SCREEN FILTER, PRESSURE CONTROL SOL FEED 319 VALVE, MANUAL
303 PIN, COILED SPRING 320 PRESSURE CONTROL SOLENOID
304 PLUG, CHECKBALL 321 CLAMP, PRESSURE CONTROL SOL. RETAINING
305 BALL, .375 DIA. 322 CLIP, PWM SOLENOID RETAINING
307 SEAL, O-RING 323 SOLENOID ASSEMBLY, PWM
308 VALVE, 3-4 SHIFT 324 VALVE, TCC REGULATOR APPLY
309 SPRING, SHIFT VALVE RETURN (2-3 AND 3-4) 325 SPRING, TCC REGULATOR APPLY VALVE
310 BOLT, SOLENOID (1-2 AND 2-3 SHIFT, PRESSURE 327 SPRING, ACTUATOR FEED LIMIT VALVE
CONTROL SOLENOID) 328 VALVE, ACTUATOR FEED LIMIT
311 2-3 SHIFT SOLENOID AND O-RING ASSEMBLY 329 PLUG, ACCUMULATOR VALVE BORE
312 VALVE, 2-3 SHIFT 330 SPRING, ACCUMULATOR VALVE
313 1-2 SHIFT SOLENOID AND O-RING ASSEMBLY 331 VALVE, ACCUMULATOR
314 VALVE, 1-2 SHIFT 333 PLATE, SPRING RETAINER
315 SPRING, 1-2 SHIFT VALVE RETURN 334 BUSHING, REVERSE BALL VALVE
316 PLUG, SHIFT SOLENOID FEED FILTER 335 BUSHING, 3RD BALL VALVE
317 FILTER, SHIFT SOLENOID FEED
SH0173-4L80-E
Figure 112 Control Valve Assem bly

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
Figure 113 Accum ulator Assem bly

501 RING, OIL SEAL (TURBINE SHAFT/STATOR HSG.)

502 SHAFT, TURBINE
503 RING, OIL SEAL (TURBINE SHAFT/FORWARD HSG.)
511 RING, SNAP
512 ROLLER CLUTCH ASSEMBLY, OVERDRIVE
513 BEARING ASSEMBLY, THRUST CARRIER/
OVERRUN CLUTCH
521 RING, SNAP
522 RING, SNAP (TURBINE SHAFT/CARRIER)
526 PLATE, 4TH CLUTCH
530 PLUG, ORIFICE
532 SPRING GUIDE AND RETAINER ASSEMBLY,
4TH CLUTCH
533 RING, SNAP (SPRING AND RETAINER ASSEMBLY
4TH CLUTCH PISTON)
534 BALL, 0.28" DIA.
535 BUSHING, OVERRUN CLUTCH HSG.
536 BUSHING, 1.12" O.D. X 0.50"
537 BALL, CHECK
R H0197-4L80-E
Figure 114 Overrun, Overdrive and 4th Clutch Assembly

643 6U 64S 646 647 ^48 6?6 649 6?6 6S0 6«7 6S]
662 663 664 665 666 648 647 66g 67q 677 67 7
530 PLUG, ORIFICE CENTER SUPPORT 643 SPACER, SUPPORT TO CASE

537 BALL, CHECK 644 ROLLER CLUTCH ASSEMBLY
601 BEARING ASM., THRUST CARRIER/FORWARD CLUTCH 645 RING, REACTION DRUM SPACER
602 HOUSING ASSEMBLY, FORWARD CLUTCH 646 RACE, THRUST BEARING TO CENTER SUPPORT
603 SEAL, CLUTCH (CENTER) 647 BEARING, NEEDLE THRUST
604 SEAL, CLUTCH (OUTER) 648 RACE, THRUST BEARING
605 SEAL, CLUTCH (INNER) 649 SHAFT ASSEMBLY, SUN GEAR
606 PISTON, FORWARD CLUTCH 650 GEAR, SUN
607 SPRING AND RETAINER ASSEMBLY 651 DRUM AND CARRIER ASSEMBLY, REACTION
608 RING, SNAP 652 WASHER, PINION THRUST (BRONZE)
609 PLATE, CLUTCH (.054 DISHED) 653 WASHER, PINION THRUST (STEEL)
610 PLATE, CLUTCH (.0775 FLAT) 654 ROLLER, NEEDLE BEARING
611 PLATE ASSEMBLY, CLUTCH 655 PINION, PLANET
612 WASHER, THRUST CLUTCH HUB HOUSING 656 PIN, PLANET PINION
613 HUB, FORWARD CLUTCH DRIVEN 657 BAND ASSEMBLY, REAR BRAKE
614 WASHER, THRUST FORWARD CLUTCH 659 WASHER, FRONT INTERNAL/REACTION CARRIER
615 HUB, DIRECT CLUTCH DRIVING 660 RING, OUTPUT SPEED SENSOR
616 RING, SNAP (6.24 O.D. X .062) 661 CARRIER ASSEMBLY, OUTPUT
617 PLATE, DIRECT CLUTCH BACKING 662 SHAFT, TRANSMISSION MAIN
618 PLATE, CLUTCH (.0915 FLAT) 663 RACE, THRUST BEARING TO SUN GEAR
619 PISTON, DIRECT CLUTCH 664 BEARING, NEEDLE THRUST RR INTERNAL GEAR
622 SEAL, CLUTCH (CENTER) 665 RACE, THRUST BEARING TO RR INTERNAL GEAR
623 HOUSING, DIRECT CLUTCH 666 GEAR, REAR INTERNAL
624 SPRAG ASSEMBLY, INTERMEDIATE CLUTCH 669 RACE, THRUST BEARING TO OUTPUT SHAFT
625 RACE, INTERMEDIATE CLUTCH (OUTER) 670 RING, SNAP MAINSHAFT INTERNAL GEAR
626 RETAINER, INTERMEDIATE CLUTCH 671 SHAFT AND BUSHING ASSEMBLY, OUTPUT
627 RING, EXTERNAL LOCKING 672 RING, SNAP (OUTPUT SHAFT/ FRONT INTERNAL GEAR)
628 BAND ASSEMBLY, FRONT 673 WASHER, THRUST
629 RING, SNAP (INTERMEDIATE CLUTCH RETAINER) 674 WASHER, THRUST SELECTIVE
630 PLATE, INTERMEDIATE CLUTCH BACKING 675 SEAL, O-RING OUTPUT SHAFT
631 PLATE ASSEMBLY, INTERMEDIATE CLUTCH 676 BUSHING, SUN GEAR SHAFT
632 PLATE, INTERMEDIATE CLUTCH 677 BUSHING, OUTPUT SHAFT
633 RING, SNAP CENTER SUPPORT/CASE 678 BUSHING
634 RING, SNAP INTERMEDIATE CLUTCH 679 BUSHING, 1.536" DIA. X 3.52“
635 SPRING AND RETAINER ASM., INTERMEDIATE CLUTCH 680 BALL, CHECK
636 PISTON, INTERMEDIATE CLUTCH 681 BUSHING, REACTION DRUM
637 SEAL, INTERMEDIATE CLUTCH (INNER) 682 SLEEVE, TRANS. OUTPUT SHAFT YOKE SEAL
638 SEAL, INTERMEDIATE CLUTCH (OUTER) 683 SEAL, OUTPUT SHAFT
639 RING, OIL SEAL 684 PLATE, CLUTCH (WAVED)
640 SUPPORT AND RACE ASSEMBLY, CENTER 685 SLEEVE AND SEAL ASSEMBLY
642 WASHER, THRUST SUPPORT/REACTION DRUM
O u U I v/27 * fL O U t
Figure 116 Internal Parts — Legend

FOR MODELS
EQUIPPED WITHOUT
NSBU SWITCH
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
Figure 117 Parking Lock and A c tu a to r A sse m bly
4L80-E OUTPUT SHAFT

IDENTIFICATION CHART
4 WHEEL NON-DOMESTIC FIXED SLIP LIGHT

DRIVE YOKE YOKE HEAVY
DUTY
S H 0200-4L80-E
Figure 118 Output Shaft Identification Chart

Figure 119 Bushing and Bearing Locations

77 BUSHING, CASE EXTENSION 601 BEARING ASM., THRUST CARRIER/FORWARD CLUTCH
78 BUSHING, TRANSMISSION CASE 644 ROLLER CLUTCH ASSEMBLY
202 BUSHING, PUMP BODY 647 BEARING, NEEDLE THRUST
233 BUSHING, STATOR SHAFT (FRONT) 664 BEARING, NEEDLE THRUST RR INTERNAL GEAR
234 BUSHING, STATOR SHAFT (REAR) 676 BUSHING, SUN GEAR SHAFT
512 ROLLER CLUTCH ASSEMBLY, OVERDRIVE 677 BUSHING, OUTPUT SHAFT
513 BEARING ASSEMBLY, THRUST CARRIER/ OVERRUN CLUTCH 678 BUSHING
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

Figure 120 Seal Locations
SEAL, O-RING (TURBINE SHAFT/TURBINE HUB) PISTON ASSEMBLY, OVERRUN CLUTCH

SEAL, OIL PUMP TO CASE SEAL, 4TH CLUTCH (INNER)
SEAL ASSEMBLY, REAR LUBE SEAL, 4TH CLUTCH (OUTER)
SEAL, EXTENSION TO CASE SEAL, CLUTCH (CENTER) (SOME MODELS)
HELIX SEAL ASSEMBLY, CASE EXTENSION SEAL, CLUTCH (OUTER)
RING, OIL SEAL SEAL, CLUTCH (INNER)
RING, OIL SEAL ACCUM. PISTON (OUTER) SEAL, CLUTCH (CENTER)
RING, OIL SEAL ACCUM. PISTON (INNER) SEAL, INTERMEDIATE CLUTCH (INNER)
SEAL, REVERSE SERVO PISTON SEAL, INTERMEDIATE CLUTCH (OUTER)
HELIX SEAL ASSEMBLY, PUMP BODY RING, OIL SEAL
RING, OIL SEAL
SEAL, (1.615) SQUARE CUT
SEAL, (.859) SQUARE CUT
RING, OIL SEAL (TURBINE SHAFT/STATOR HSG.)
RING, OIL SEAL (TURBINE SHAFT/FORWARD HSG.)
FASTENER APPLICATION ASSEMBLY TORQUE
N«m Lb.-Ft. Lb.-ln.
SOLENOID TO VALVE BODY.............................................................. 8 — 71
CONTROL VALVE ASSEMBLY TO CASE.......................................... 11 — 97
OIL TEST HOLE PLUG ......................................................................... 11 — 97
FLYWHEEL HOUSING COVER TO TRANSMISSION........................ 7 — 62
PUMP BODY TO COVER...................................................................... 24 18 —

PUMP ASSEMBLY TO CASE............................................................... 24 18 —
REAR SERVO COVER TO CASE.......................................................... 24 18 —
PRESSURE CONTROL SOLENOID BRACKET TO VALVE BODY...... 8 — 71
PARKING PAWL BRACKET TO CASE................................................ 24 18 —

ACCUMULATOR HOUSING TO VALVE BODY................................. 11 — 97
FOURTH CLUTCH ................................................................................ 23 17 —
PAN TO CASE....................................................................................... 24 18 —
EXTENSION HOUSING TO CASE...................................................... 34 25 —
MANUAL SHAFT TO DETENT LEVER N U T ...................................... 24 18 —
SPEED SENSOR AND BRACKET ASSEMBLY TO CASE ................. 11 — 97
CASE CENTER SUPPORT.................................................................... 43 32 —
FLYWHEEL TO CONVERTER............................................................... 44 32 —
TRANSMISSION CASE TO ENGINE.................................................. 44 32 —
COOLER PIPE CONNECTOR NUT AT CASE AND RADIATOR......... 38 28 —
VALVE BODY TO CASE / LUBE PIPE................................................. 11 — 97
ENGINE REAR MOUNT TO TRANSMISSION BOLT........................ 44 32 —
ENGINE REAR SUPPORT BRACKET TO FRAME NUT..................... 44 32 —
VALVE BODY TO CASE / P SM ........................................................... 11 — 97
DRAIN PLUG, OIL PAN ........................................................................ 34 25 —
RH0203-4L80-E-R1
SPECIAL TOOLS
Overrun Clutch Piston Seal Protector Rear Lube Seal Installer Compressor Adapter
(Used with J 23327-1)
J 38729 38693 J 25018-A
Forward Clutch Spring Compressor Oil Pump Seal & Rear Extension Housing Gear Unit Assembly Installer/Remover
Seal (Fixed Yoke) Installer (Used with J 6125-1B)
J 23327-1 J 38694 J 38868
Intermediate Clutch Inner Seal Protector Direct Clutch Spiral Snap Ring Placer
J 6116-01 J 21363 J 38695
5/16-18 Thread with 3/8-16 Adapter Support Adapter Forward Clutch Assembly Remover &
(Set of 2) (Used with J 6116-01) Installer
J 6125-1B J 21364-A J 38358-A
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 25025 J 21370-10 39195

Magnetic Base Band Transmission Holding Fixture
ADA PTER
J 26900-13 J 38737
Intermediate Clutch Pack Center Support Tool Snap Ring Remover

Alignment Tool
J 24396 J 23093 J 28585
Case Extension Seal Installer (Slip Yoke) Seal Remover

(Use with J 6125-1B)
J 38869 J 23129 SH0204-4L80-E

SPECIAL TOOLS (CONT.)

Fourth Clutch Piston & Housing Seal Intermediate Clutch Piston Oil Pump Assembly Seal Ring Installer
Protectors/Spacer Compressor Adapter
PUSHER
PROTECTOR PRO TECTO R SPACER INSTALLER
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
J 38732-1 J 21362-1 J 38735-1 J 38735-3 J 38882
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
J 36850 J 38736-5 J 38736-6 J 21369-40 J 21369-3 J 21369-6
Center Support Reamer and Pin Gage Torque Converter Holding Strap
REAMER PIN GAG E
c
J 39919-1 J 39919-2 J 21366
SH0205-4L80-E
THIS PAGE LEFT

INTENTIONALLY BLANK
BORG-WARNER T5 MANUAL TRANSMISSION 7B6-1
SECTION 7B6
BORG-WARNER T5 MANUAL
TRANSMISSION
The correct torque value m u st be u se d when installing fasteners that require it. If the above conditions
CONTENTS
SUBJECT PAGE
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
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
Figure 1—Transmission Case Components

• Roller bearings support the mainshaft indepen PRECAUTIONS
dently in the drive gear.
• The drive gear and mainshaft are engaged by a Certain precautions should be followed when repair
synchronizer for direct drive in fourth gear. ing the transmission. Unless proper care is taken, the
• Thrust washers limit the play of the mainshaft. components may be damaged.
4. Reverse idler gear. • Repair of a transmission should be done in a clean

work area. The outside of the case should be clean
• The idler gear drives the mainshaft in reverse.
to keep dirt out of the transmission. On transmis
• The idler gear is supported on its own shaft.
sions with a standard gearshift lever, install the
5. Shift lever. lever before cleaning the outside of the transmis
sion.
• The shift lever is mounted on the extension
• During transmission repair, all the parts should be
housing.
cleaned in cleaning solvent and then air dried. Wip
• The shift lever moves the shafts which are
ing cloths or rags should not be used to dry the
mounted in the transmission top cover and
parts as lint may get on the parts and cause trou
case. ble later. All the parts, except those being worked
• Shift forks mounted on shafts move the syn
on, should be kept covered with clean paper.
chronizers to engage the gears.
• A pin-type interlock blocks the other shafts
when one is moved.
Figure 2—Transmission Gear Components
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.
Tools Required: important

J 22912-01 Bearing and Gear Puller
J 37359 Countershaft Bearing Remover • The offset lever is engaged into the extension
• Remove drain bolt and drain the lubricant. housing and cannot be removed when the
extension housing is mounted to the transmis
NOTICE: Rem oval o f o ffset lever in position sion.
other than neutral (centered) m ay result in
driving the roll pin into the detent plate with 5. Detent ball and the spring from the offset lever
out releasing the lever, m aking further disas (figure 4).
sem bly extrem ely difficult. 6. Pin from extension housing or the offset lever.
7. Oiling funnel from rear of countershaft (figure 5).
• Position offset lever in neutral gate (centered). 8. Bolts attaching transmission cover and shift fork
1. Control lever. assembly to the case.
• Boot and the dust cover.
Figure 3—Removing the Offset Lever Pin Figure 5—Oiling Funnel
Figure 6—Fifth Speed and Reverse Shift Lever

Retaining Clip
Important
16. Snap ring from the mainshaft (figure 9).
• Two of the cover mounting bolts are alignment • Mark the front bearing retainer and the case for
bolts. Note the positions that they were alignment.
removed from for reassembly. 17. Front bearing retainer bolts.
18. Front bearing retainer.
9. Cover from the case.
19. Front bearing race and the shim pack (figure 10).
10. Reverse lever spring clip, pivot bolt, and shift lever
20. Main drive gear.
(figure 6).
11. Backup lamp switch. • Turn the gear so the cutout is toward the coun
12. Fifth gear synchronizer snap ring and retainer from tershaft (figure 11).
the rear of the countershaft (figure 7). •B e careful not to drop the 15 roller bearings,
13. Reverse lock spring from front of transmission case thrust bearing, or race from the rear of the drive
by unhooking it (figure 8). gear.
14. Fifth gear, synchronizer, shift fork, and shift rail as 21. Fourth gear blocker ring from third/fourth synchro
an assembly. nizer.
22. Mainshaft rear bearing race.
• If necessary, rotate rail to disengage it from
• If the race sticks, it is probably misaligned in
reverse lever assembly.
the case bore. To free the race, work the shaft
15. Speedometer gear and retaining clip. back and forth.
Figure 8— Fifth Gear and Reverse Shift Rail Figure 10—Main Drive Gear Shim Pack
23. Mainshaft (figure 12).

MAINSHAFT DISASSEMBLY
• Tilt mainshaft upward and remove assembly
from the transmission case. Disassemble (Figures 16 through 18)
24. Reverse fork assembly from the transmission case.
*
25. Countershaft retainer and shims (figure 13). Tool Required:
26. Roll pin from the forward end of the reverse idler J 22912-01 Bearing and Gear Puller
shaft (figure 14).
1. Thrust bearing and the race from the front of the
27. Reverse idler shaft, rubber O-ring, and gear from
main shaft.
the transmission case.
28. Rear countershaft bearing race. • Scribe a reference mark on the third-fourth syn
29. Countershaft bearing using J 8433 with J 22912-01 chronizer hub and sleeve for reassembly.
and J 37359 (figure 15).
2. Third-fourth synchronizer, third blocker ring, sleeve,
9 Important hub, and third gear as an assembly from the main
shaft using J 22912-01 and a press (figure 16).
• Note the direction the bearing faces. 3. Needle bearing assembly and spacer (figure 17).
4. Second gear snap ring and thrust washer.
30. Countershaft. 5. Second gear, spacer, and needle bearing.
• Move the countershaft assembly rearward, tilt it 6. Spiral snap ring.
upward, and remove from case. 7. Thrust washer.
Figure 13—Countershaft Retainer
Figure 14—Removing the Reverse Idler Shaft Pin
14. Needle bearing and sleeve.

Figure 12—Mainshaft Removal 15. Locating pin.
16. Three-piece first gear blocker ring assembly.
8. Three-piece second gear blocker ring assembly
(figure 18).
DRIVE GEAR DISASSEMBLY
• Scribe a reference mark on first-second syn
chronizer hub and sleeve for reassembly.
9. First-second synchronizer spring and keys from
first-reverse sliding gear. Tool Required:
10. Sleeve from mainshaft hub. J 22912-01 Bearing and Gear Puller
1. Bearing race.
Important 2. Thrust bearing.
3. Roller bearings from cavity of drive gear.
• Do not attempt to remove the first-second-re- 4. Bearing from the drive gear using J 22912-01 and
verse hub from the mainshaft. The hub and a press (figure 19).
shaft are permanently assembled and machined
as a matched set. jj^j Clean
11. Fifth gear using J 22912-01 and a press,
12. Mainshaft rear bearing assembly. • All parts in a suitable solvent. Do not spin the bear
13. First gear. ings dry.
J 22912-01
8433
Figure 15—Countershaft Bearing Removal Figure 17—Needle Bearing and Spacer
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.
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
• Fifth-gear blocker ring for wear and damage.

Third-Forth Blocker Rings
1. Third-gear blocker ring to third gear with twisting

motion to fully seat.
2. Fourth-gear blocker ring to drive gear with twisting
motion to fully seat.
Measure
Gap between vertical faces of blocker teeth and

clutch teeth. Nominal gap is 0.88 - 1.50 mm (0.035
Figure 20— Removing the Main Drive Gear Bearing - 0.059 inch) for new blocker rings.
3. Lubricate bearings with Dexron® III or equivalent

transmission fluid.
V Inspect
• Bearings for roughness by slowly turning race by

hand.
SYNCHRONIZER BLOCKER RINGS
The first-second synchronizer outer cone and the
third-fourth blocker ring are lined with friction material
and cannot be checked visually for wear. Replacement
is necessary when the gap between blocker teeth and
adjacent clutch teeth is significantly less than specified.
Fifth gear blocker ring is brass and can be checked
visually for wear and damage.
Important
Make certain the blocker rings are correctly

identified before assembly. The first-second
synchronizer blocker ring does not have friction
First-Second Blocker Rings SYNCHRONIZER KEYS AND

* Assemble (Figures 21 and 23) SPRINGS
Important (Figures 22 through 25)
1. Three-piece first-gear blocker ring assembly using
a twisting motion to fully seat.
2. Three-piece first-gear blocker ring assembly with The synchronizer hubs and sliding sleeves are a
needle bearing and bearing sleeve to first gear. selected assembly and should be kept together as
3. Three-piece second gear blocker ring assembly originally assembled. The keys and springs may be
using a twisting motion to fully seat. replaced if worn or broken.
with thrust washer to second gear.
Measure 1. Keys and springs.

• Mark hub and sleeve for reassembly.
• Gap between vertical faces of blocker teeth and • Push the sliding sleeve from the hub. The keys
clutch teeth. Nominal gap is 0.81 - 1.40 mm will fall free and the springs may be easily
(0.032 - 0.055 inch) for new blocker ring assem removed.
blies.
-►+ Install or Connect
1. Keys and springs.

• Place a blocker ring on side of the hub and
sleeve and install keys and retain with a spring.
• Place blocker ring on opposite side of the hub
and sleeve and install remaining spring.
EXTENSION HOUSING OIL SEAL

AND BUSHING REPLACEMENT
Tool Required:
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.
3. Bushing if it is worn or damaged, using J 8092 and

J 23062-14.
Inspect
1. Extension for scoring, wear or cracks, especially at

the flange.
J 21426
+«- Install or Connect (Figures 26 and 27)
Tools Required:
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.
DRIVE GEAR BEARING

RETAINER OIL SEAL
1. Seal.
2. Sealing compound from flange of retainer.
i? Inspect
1. Retainer nose for scoring, wear, or cracks, espe

cially at the flange.
2. Replace the retainer if it is worn or damaged.
*4 - Install or Connect (Figure 28)
Tool Required:
J 37375 Bearing Retainer Seal Installer
Figure 28—Main Drive Gear Bearing Retainer Oil

Seal
• New seal using J 37375.

• Lubricate the inside diameter of the seal with
transmission oil.
TRANSMISSION COVER
• The shift rail and shift fork plates must be in the

neutral position (centered).
1. Turn the shift rail until the selector arm is disen
gaged from the fork plates.
2. Drive the retaining pin out of the selector arm.
3. Remove the shift rail, shift forks, shift fork plates,
selector arm, interlock plate, and roll pin.
Figure 26—Installing the Extension Housing 4. Pry the transmission cover to extension housing oil
Bushing seal out.
• The shift arm retaining pin hole must be away

from the cover and to the rear.
• Push the shift fork through the arm.
5. Third and fourth shift fork.
• Hold the shift fork in the cover with fork offset to
the rear.
• The fork plate must be under the first and sec
ond shift fork plate.
• Push the shift rail through the fork, into the cov
er front bore.
6. Turn the shift rail until the front fork plate is away
from the cover and parallel to it.
7. Drive a new retaining pin into the selector arm and
the shift rail.
• Be sure the arm and shaft pin holes are align
ed.
• The retaining pin must be flush with the selector
arm.
8. Install a new oil seal.
Figure 29—Transmission Cover • Coat the seal with transmission oil.
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
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.
Assemble (Figure 29)

&
• Coat the shift rail and the cover bores lightly with
transmission assembly grease.
1. Install a new shift rail plug, if needed.
• Coat the outside of the plug with sealing com
pound.
2. Fit the inserts and the fork plates into the shift
forks.
3. First and second (largest) shift fork.
• Fit the shift rail into the cover rear bore.
• Hold the shift fork in the cover with the fork
offset to the rear.
• Push the shift rail through the fork.
4. Selector arm and the interlock plate.
• Hold the selector arm and the interlock plate in
the cover with the widest part of the plate away
from the cover. Figure 30— Removing Bearing Race from the Case
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).
Install or Connect (Figures 32, and 33)
Tools Required:
J 37357 Countershaft Bearing and Race
Remover and Installer
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 6133-01 Installer
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
Tool Required: Before pressing components together, make sure

J 25234 Front and Rear Bearing Installer the synchronizer hub faces the short end of the
J 37360 Spiral Snap Ring Installer mainshaft. Hold third gear against the synchronizer
J 37372 Synchronizer and Gear Installer to maintain blocker ring alignment with keys.
Important
TRANSMISSION ASSEMBLY
• If replacing first-second or third-fourth synchronizer +4- Install or Connect (Figures 6 through 14, 34,
blocker rings, soak new blocker ring assemblies for
10 minutes in Dexron® III or equivalent before 35, and 36)
assembly on mainshaft.
• Coat mainshaft and gear bores with transmis NOTICE: For ste p s 5, 17, 20, 23, 29, 30, and
sion lubricant. 32, refer to “N otice” on page 7B6-1.
1. First-second synchronizer sleeve on mainshaft hub.
• Align marks made during disassembly. Tools Required:
J 37 3 5 7 C ountershaft Bearing and Race
Important Remover and Installer
• Use care in synchronizer spring placement. If syn J 37372 Synchronizer and Gear Installer
chronizer is assembled with improper spring place J 8001 Dial Indicator
ment, hard shifting will result. 1. Countershaft into case.
2. Rear countershaft bearing to countershaft using
2. First-second synchronizer keys and springs.
J 37372 and a press (figure 34).
• Engage tang end of each spring in the same • Support the countershaft with J 37357.
synchronizer key, but position open end of
springs opposite of each other. Important
3. Three-piece first gear blocker ring assembly.
4. Locating pin into the main shaft. Failure to properly support the countershaft may
5. Sleeve and needle bearing into mainshaft, aligning result in permanent distortion of the case during
notch in sleeve with locating pin. installation.
6. First gear.
• Align slots in first gear with tabs on blocker ring
assembly.
7. Rear mainshaft bearing with taper facing rear of
shaft.
8. Fifth gear onto mainshaft using J 25234 and a
press.
• Lubricate fifth-gear splines with petroleum jelly.
• Carefully align the mainshaft and gear splines.
If splines are improperly aligned, damage could
occur when the gear is pressed onto the main
shaft.
9. Fifth gear snap ring (figure 9).
and thrust washer.
11. Spiral snap ring using J 37360.
12. Second gear spacer, needle bearing, and gear.
• Align slots in second gear with tabs on blocker
ring assembly.
13. Second gear thrust washer and snap ring.
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.
• Retainer bolts to 20 N-m (15 lbs. ft.). Tighten

&
• Bend tabs over the four attaching bolts.
6. Reverse shift fork in the case. • Pivot bolt to 27 N-m (20 lbs. ft.).
7. Mainshaft into the transmission case (figure 12). 18. Backup lamp switch.
8. Rear mainshaft bearing race. • Coat threads with pipe thread sealant GM P/N
9. Drive gear into the case (figure 11). 1052080 or equivalent.
• Make sure rollers, thrust bearing, and washer 19. Transmission cover.
are in place.
A. Move the shift forks and the synchronizers to
• Be sure to engage the third-fourth synchronizer the neutral positions.
sleeve and blocker ring. B. Apply a 3 mm (1/8-inch) bead of RTV sealant
10. Front bearing race in the front bearing retainer. GM P/N 12345739, or equivalent, sealer to the
• Do not install shims in front bearing retainer at cover mating surface.
this time. C. Lower the cover onto the case, aligning the shift
forks into the synchronizers.
20. Transmission cover bolts.
• Install the two locating bolts in the holes they
were removed from first.
St Tighten
• Cover bolts to 13 N-m (115 lbs. in.).

21. Extension housing.
A. Apply a 3 mm (1 /8-inch) diameter bead of RTV
sealant GM P/N 12345739, or equivalent, seal
er to the mating surface.
B. Coat detent spring with petroleum jelly and
insert in offset lever.
C. Lubricate detent plate and install detent ball in
neutral position on plate.
D. Position offset lever in extension housing with
spring over detent ball.
E. Slide lever and extension housing into position
as an assembly.
22. Extension housing vent.
23. Extension housing bolts.

A. Press downward on offset lever to compress
detent spring and push lever and housing into
position.
B. Apply pipe thread sealant GM P/N 1052080 or
equivalent to threads of bolts.
$ Tighten
• Extension housing bolts to 30 N-m (22 lbs. ft.).

24. New pin into the offset lever and shift rail (figure 1).
25. Damper sleeve in offset lever.
• Turn transmission on end and mount a dial indica
tor J 8001 on the extension housing with the indi
cator on the end of the mainshaft.
Measure
• Mainshaft end play (figure 36).

• Rotate the mainshaft and zero the dial indicator. 29. Retainer bolts.
Pull upwards on the mainshaft until end play is
& Tighten
removed and record reading.
• Ideal mainshaft end play is zero with ± 0.02 mm
• Retainer bolts to 20 N-m (15 lbs. ft.).
(0.001 inch) allowable.
30. Drain plug.
• To set preload, select a shim pack equal to the •Apply pipe sealant GM P/N 1052080 to the
dial indicator reading recorded. treads of the drain plug.
26. Remove front bearing retainer and front bearing Tighten
race.
27. Install necessary shim(s) and reinstall bearing race • Drain plug to 27 N m (20 lbs. ft.).
(figure 10). 31. Fill the transmission to the proper lever with Dex-
• Apply a 3 mm diameter (1/8 inch) bead of RTV ron® III transmission fluid or equivalent.
sealant GM P/N 12345739 or equivalent on 32. Fill plug.
case mating surface of front bearing retainer. •Apply pipe sealant GM P/N 1052080 to the
treads of the fill plug.
28. Bearing retainer.
Tighten
•Apply pipe sealant GM P/N 1052080 to the
treads of the retainer bolts. Fill plug to 27 N-m (20 lbs. ft.).
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
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
1. DIAL INDICATOR 9. COUNTERSHAFT BEARING AND RACE

2. UNIVERSAL DRIVER HANDLE REMOVER AND INSTALLER
3. EXTENSION HOUSING SEAL INSTALLER 10. BEARING RACE RECIEVER AND CASE SUPPORT
4. BEARING AND GEAR PULLER 11. COUNTERSHAFT BEARING REMOVER
5. EXTENSION HOUSING BUSHING 12. SPIRAL SNAP RING INSTALLER
REMOVER AND INSTALLER 13. SYNCHRONIZER AND GEAR INSTALLER
6. FRONT AND REAR BEARING INSTALLER 14. DRIVE GEAR BEARING RETAINER
7. HOLDING FIXTURE SEAL INSTALLER
8. INSTALLER 15. HEAVY DUTY PULLEY PULLER
3707r5105
NEW VENTURE GEAR N V 3500 MANUAL TRANSMISSION 7B7-1
SECTION 7B7
NEW VENTURE GEAR NV3500 MANUAL

TRANSMISSION
be used. Fasteners that are not reused, and those requiring thread locking com pound will b e called out.
CONTENTS
SUBJECT PAGE
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
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
Figure 1—Transmission Shift Mechanism and Case Components - Legend

Figure 2—Transmission Shift Mechanism and Case Components
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.
Figure 3—Transmission Gear Components
• 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
1. SHAFT, INPUT 36. SLEEVE, SYNCHRONIZER

2. RING, SYNCHRONIZER 37. RING, SNAP
3. BEARING, PILOT 38. RING, SYNCHRONIZER
4. RING, SNAP 39. BEARING ASSEMBLY, 5TH GEAR
5. SLEEVE, SYNCHRONIZER SPEED NEEDLE
6. BALL, SYNCHRONIZER DETENT 40. GEAR ASSEMBLY, 5TH SPEED
7. SPRING, SYNCHRONIZER DETENT 41. RETAINER, OUTPUT SHAFT
8. KEY, SYNCHRONIZER BEARING (2WD)
9. HUB, 3 - 4 SYNCHRONIZER 42. BEARING ASSEMBLY, OUTPUT
10. RING, SYNCHRONIZER SHAFT (2WD)
11. GEAR ASSEMBLY, 3RD SPEED 43. RING, SNAP
12. BEARING ASSEMBLY, 3RD SPEED 44. ROTOR, SPEED SENSOR
GEAR NEEDLE 45. BOLT (4WD)
13. RETAINER RING 46. RETAINER, OUTPUT SHAFT
14. THRUST WASHER 2 - PIECE BEARING (4WD)
15. BEARING ASSEMBLY, SPEED 47. BEARING ASSEMBLY, OUTPUT
GEAR NEEDLE SHAFT (4WD)
16. GEAR ASSEMBLY, 2ND SPEED 48. RING, SNAP
17. CONE, SYNCHRONIZER REACTION 49. HOUSING, FRONT
18. CONE, SYNCHRONIZER 50. RACE, COUNTERSHAFT BEARING
19. RING, SYNCHRONIZER BLOCKER 51. BEARING, COUNTERSHAFT
20. RING, SYNCHRONIZER INTERIM 52. COUNTERSHAFT ASSEMBLY
21. SLEEVE, 1 - 2 SYNCHRONIZER 53. RING, SNAP
22. HUB, 1 - 2 SYNCHRONIZER 54. SHAFT, REVERSE IDLER
23. RING, SYNCHRONIZER BLOCKER 55. BALL, LOCATING
24. CONE, SYNCHRONIZER 56. WASHER, THRUST
25. CONE, SYNCHRONIZER REACTION 57. GEAR, REVERSE
26. RING, SYNCHRONIZER BLOCKER 58. BEARING ASSEMBLY, NEEDLE
27. GEAR, 1ST SPEED 59. WASHER, THRUST
28. BEARING ASSEMBLY, SPEED 60. WASHER, SPRING
GEAR NEEDLE 61. WASHER
29. SHAFT, OUTPUT (4WD) 62. RING, SNAP
30. SEAL, 5TH SPEED GEAR DRAG 63. SUPPORT, IDLER SHAFT
31. BEARING ASSEMBLY, SPEED 64. BEARING, COUNTERSHAFT
GEAR NEEDLE 65. RACE, COUNTERSHAFT BEARING
32. SEAL, REVERSE GEAR SPEED DRAG 66. BOLT, HOUSING
33. GEAR ASSEMBLY, REVERSE SPEED 67. BOLT, IDLER SHAFT SUPPORT
34. RING, SPIRAL LOCK 68. BOLT (2WD)
35. HUB, 5TH - REVERSE SYNCHRONIZER 69. HOUSING, REAR
Figure A— Transmission Gear Components -Legend
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
Figure 8—Removing 4WD Oil Seal Figure 10—Removing the Front Housing
6. Second gear bearing assembly (figure 18).

MAINSHAFT DISASSEMBLY • Leave the synchronizer cone on the first-second
synchronizer assembly to prevent the synchro
❖ Disassemble (Figures 17 through 21)
nizer detent balls from popping out.
7. Synchronizer interim ring, reactor cone, blocker
Tools Required:
ring, and synchronizer cone from the mainshaft
Hydraulic Press
(figure 18).
J 22912-01 Gear and Bearing Separator Plate
8. Snap ring (figure 19).
1. Snap ring (figure 17). 9. First speed gear and first-second synchronizer
2. Third-fourth synchronizer assembly, synchronizer assembly using J 22912-01 and hydraulic press
rings, and third speed gear using J22912-01 and (figure 19).
hydraulic press (figure 17).
A. Scribe on hub and sleeve so the parts can be
A. Scribe on hub and sleeve so the parts can be reinstalled in the same position.
reinstalled in the same position. B. Leave the synchronizer rings on the first-second
B. Leave the synchronizer rings on the third-fourth synchronizer assembly to prevent the synchro
synchronizer to prevent the synchronizer detent nizer detent balls from popping out.
balls from popping out. 10. Synchronizer cone, blocker ring, reaction cone, and
3. Third gear bearing assembly (figure 17). interim ring from mainshaft (figure 19).
4. Collar and spacers (figure 18). 11. First gear bearing assembly (figure 19).
5. Second speed gear assembly (figure 18). 12. Fifth speed gear (figure 20).
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.
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.
Figure 16—2WD Rear Bearing Figure 18— Removing Third-Fourth Gear

Components
FRONT HOUSING DISASSEMBLY
3. Clutch fork pivot assembly, using J 36510 and
J 6125-1B (figure 25).
A. Put an additional nut (3/8-16 thread) onto
Tools Required: J 36510 and thread J 6125-1B onto nut.
J 36183 Input Shaft Press Tube with Cap B. Tighten both nuts.
J 36184 Adapter Press Tube Reducer C. Slide hammer out pivot.
J 23907 Slide Hammer with Pilot Bearing Puller 4. Two detent plunger bushings, if necessary, using
J 6125-1B Slide Hammer J 36507 (figure 26).
J 36510 Clutch Fork Pivot Remover/Installer
J 36507 Detent Bushing Remover and Installer • Remove ONE bushing at a time.
J 36800 Shift Rail Busing Remover 5. Breather assembly.
J 36511 Oil Fill Plug Hex Bit (17 mm)
• Do NOT remove metal tube from case.
1. Press out input shaft bearing using J 36183,
J 36184 and hydraulic press. 6. Oil fill plug and oil drain plug using J 36511 (figure
2. Shift rail front housing bushing using J 36800 and 27).
J 23907 (figure 24). 7. Gasket material from the case using liquid gasket
remover.
Figure 19— Removing Second Gear Components Figure 21—Removing Reverse Gear Components
Figure 20— Removing Fifth Gear Components Figure 22—Synchronizer Assembly
REAR HOUSING DISASSEMBLY C. Slide hammer out.

— If the bearing lip breaks off, position puller
Disassemble (Figures 28, 29, and 30) legs behind the inside (outer end) bearing
❖ lip and repeat procedure.
Tools Required: 2. Drive out dowel pins.
Hydraulic Press 3. Three bolts, output shaft bearing retainer, and
J 23907 Slide Hammer with Pilot Bearing Puller bearing assembly, using brass drift (4WD models
J 26941 2WD Output Shaft Oil Seal Remover only) (figure 29).
(2WD models only) 4. Slip yoke seal, using J 26941 and J 23907 (figure
1. Rear housing shift shaft bearing, using J 23907 30) (2WD models only).
with pilot bearing puller (figure 28). 5. Gasket material from the case using liquid gasket
A. Position puller legs behind bearing lip. remover.
B. Tighten.
7B7-10 NEW VENTURE GEAR N V 3500 MANUAL TRANSMISSION
NEW VENTURE GEAR N V 3500 MANUAL TRANSMISSION 7B 7-11

MAINSHAFT AND • Nicks.
• Chipped gear teeth or high spots (a small shiny
SYNCHRONIZERS spot on the gear teeth mating surface) that
could cause gear noise.
Clean 2. Related surfaces on the gears like thrust faces and
bearing surface diameters.
All parts in a suitable solvent and air dry. 3. Synchronizer sleeves for:
• A sliding fit on the synchronizer hubs and for
Important the hubs to have a force fit on the mainshaft
splines. Replace the hub(s) if they do not
• Do not spin dry ball bearings. require a force fit on the mainshaft.
4. Synchronizer springs and keys for:
Inspect • Damage.
5. Synchronizer rings for:
1. Gears for:
• Excess wear.
• Cracks. 6. Synchronizer clutching teeth for:
• 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.
REVERSE IDLER GEAR

g| Clean
• All parts in a suitable solvent and air dry.
Inspect
1.G ear teeth for scuffed, nicked, burred, broken

teeth,or high spots (a small shiny spot on the gear
teeth mating surface) that could cause gear noise.
2. Bearing assembly for roughness of rotation, burred,
or pitted condition and cage damage. Replace if
these conditions exist.
3. Shaft, for scoring, wear, or overheating.
• If scuffed, nicked or burred conditions cannot
be removed with a soft stone or crocus cloth,
replace the component.
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)
The gasket material from the machined mating sur

face with liquid gasket remover.
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 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.
REAR HOUSING ASSEMBLY

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.
NOTICE: Refer to “N otice” on page 7B1-1.
2. Bearing assembly using brass drift (4WD models

only).
Figure 36—Installing 2WD Slip Yoke Seal
Output shaft bearing retainer.

Three bolts. Apply threadlocker GM P/N
12345382 or equivalent to the threads.
Tighten

3. Two dowel pins.
• Drive until flush.
4. Slip yoke oil seal using J 36503 (figure 36) (2WD
models only).
• Fill between the seal lips with chassis grease.
FRONT HOUSING ASSEMBLY

* Assemble (Figures 27, 37, 38, and 39)
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
• Drain plug to 60 N-m (44 lbs. ft.).
REVERSE IDLER GEAR

ASSEMBLY
* Assemble (Figure 23)
• Lubricate all components as assembly progresses.

Use lubricant Synchromesh Transmission Fluid GM
P/N 12345349 or equivalent.
1. Snap ring onto shaft.
2. Wave washer.
3. Locating ball.
4. thrust washer.
J 36510 Clutch Fork Pivot Remover/Installer 5. Bearing assembly.
J 36507 Detent Bushing Remover and Installer 6. Reverse Idler gear.
J 36511 Oil Fill Plug Hex Bit (17 mm) 7. Locating ball.
J 36798-1 Shift Shaft Bushing Installing Tool 8. Thrust washer.
J 36190 Drive Handle 9. Snap ring.
1. Press in bearing until snap ring is seated using
J 36183, J 36184, and hydraulic press. SYNCHRONIZER ASSEMBLY
2. Shift shaft front housing bushings using J 36798-1
and J 36190 (figure 37). * Assemble (Figure 22)
3. Clutch fork pivot assembly using J 36510 and
J 36190 (figure 38). 1. Sleeve onto hub.
4. Two detent plunger bushings, using J 36507 (figure • Check scribe marks for correct positions.
39). • Remove spiral lock ring for easier assembly
A. Install the first bushing until the second scribe (fifth-reverse only).
mark on the tool is aligned with the housing. 2. Spring into key.
B. Install the second bushing until the first scribe • Assembly into the hub.
mark on the tool is aligned with the housing. 3. Position assembly as in view A (figure 22).
5. Breather assembly. 4. Balls.
• Push the ball into the sleeve using a screwdriv
NOTICE: Refer to “N otice” on page 7B1-1. er.
• Push the sleeve down just enough to retain the
ball.
• Slide the sleeve up just enough to install each
of the two remaining balls (on at a time).
5. Synchronizer rings.
• Make sure synchronizer ring tangs line up with
the keys.
6. Center the hub, keys and balls by pushing on the
synchronizer rings. Balls will “click” into position.
• Install spiral lock ring (fifth-reverse only).
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
Figure 42— Installing Reverse Gear Components
Important
The assembly of some components will require use

of an assembly lube. It is recommended that
TRANSJEL ™ J 36850 or equivalent be used dur
ing assembly.
Heat the 2WD speed sensor rotor for 7-10 minutes
at 120°C (250°F) prior to installation during assem
bly procedures.
Fifth gear drag seal onto the mainshaft using
J 39924-2 (figure 40).
Reverse gear drag seal onto the reverse gear
using J 39924-1 (figure 41).
Bearing assembly and reverse speed gear (figure
42).
When pressing the fifth-reverse synchronizer
assembly:
A. Manually align and engage splines.
B. Press until seated.
C. Be sure all shavings are removed.
Figure 43 —Installing Fifth Gear
5. Fifth-reverse synchronizer assembly with synchro
nizer ring using J 36183 and J 36184 and a
• Check scribe marks for correct positions.
• Position spiral lock ring towards reverse speed
gear.
6. NEW snap ring.
7. Bearing assembly and fifth speed gear (figure 43).
8. Bearing assembly and first speed gear (figure 44).
9. Synchronizer interim ring, reactor cone, blocker
ring and synchronizer cone (figure 44).
10. When pressing the first-second synchronizer
assembly:
B. Start press operation, STOP before tangs
engage.
C. Lift and rotate gear to engage synchronizer
ring.
D. Continue to press until seated.
Figure 41— Reverse Gear Drag Seal Installer E. Be sure all shavings are removed.
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.
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
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.
Figure 47—Mainshaft Components Installation Figure 49—Installing 2WD Rear Housing
1. Pilot bearing into input shaft (figure 47). 9 Important

A. Turn the smaller diameter of the bearing cage
toward the input shaft. • Steps 8 through 13 are for 2WD models only.
B. Retain with TRANSJEL ™ J 36850 or equiva Steps 14 through 16 is for 4WD models only.
lent.
8. Speed sensor rotor HEATED (2WD models only)
2. Position onto J 36515-15/J 36515 fixture (figure
47): • If necessary seat with J 6133-01.
A. Input shaft.
B. Pilot bearing. 9 Important
C. Synchronizer ring.
D. Mainshaft assembly. • The 2WD rear housing output shaft bearing
3. Position countershaft onto J 36515-16 fixture (fig assembly bore MUST be heated for 3 to 5 min
ure 14). utes with J 25070 before assembly (figure 48).
4. Reverse idler assembly (figure 14).
5. Output shaft bearing assembly (2WD models only) 9. J 36515-10 through bolt and holes in the rear
(figure 16). housing (figure 49) (2WD models only).
6. New snap ring (figure 16). • Screw into the output shaft bearing retainer.
7. Install on main shaft assembly (figure 14): • Notch in retainer towards oil delivery tube
A. First-second shift fork. assembly.
B. 5-reverse shift fork.
Figure 50—Installing 2WD Rear Bearing Retainer

Figure 48— Heating 2WD Rear Main Bore Bolts
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.
• Bring the housing straight down. If resistance is Important

felt at about 7 mm (1/4 in.), then the rollers are
cocked. Repeat above procedures to install. Do • The remaining assembly procedures apply to both
not force housing down. 2WD and 4WD models.
12. Bolts (figure 50) (2WD models only). 16. Lay the unit down on the workbench and remove
A. Apply pipe sealant with Teflon ™ GM P/N J 36515, J 36515-15, and J 36515-16.
1052080 or equivalent to the bolt holes of the 17. Idler shaft support and bolts (figure 52).
rear housing. A. Line up the bolt threads in the idler shaft sup
B. Apply threadlocker GM P/N 12345382 to bolt port with bolt hole.
threads. B. Apply pipe sealant with Teflon ™ GM P/N
C. Remove J 36515-10. 1052080 or equivalent to the bolt hole.
C. Apply threadlocker GM P/N 12345382 or equiv
Tighten alent to the bolt threads.
D. Hold reverse idler shaft against idler support
• Bolts to 22 N-m (16 lbs. ft.). while torquing.
13. Countershaft bearing (4WD models only).
A. Install in bearing race of the housing. Tighten
B. Install the smaller diameter of the bearing cage
into the bearing race. • Bolt to 22 N-m (16 lbs. ft.).
C. Retain with TRANSJEL ™ J 36850 or equiva 18. Position J 8763-21, J 8763-02, and J 36824 onto
lent. the transmission case (figure 11).
Figure 51—Installing 4WD Rear Housing Oil Seal Figure 52—Installing Reverse Idler Support
7B7-20 NEW VENTURE GEAR N V 3500 MANUAL TRANSMISSION
19. Third-fourth shift fork onto the third-fourth synchro

nizer sleeve.
• Align all three insert notches.
20. Shift shaft into third-fourth shift fork with detent
reliefs in shaft pointing out.
21. Shift lever and block-out bushing onto the shift
shaft .
22. Shift shaft through first-second shift fork (figure 31).
23. Shift socket onto the shift shaft.
• Slide the shift shaft all the way into the case.
24. New roll pin into shift lever (figure 31).
• Rotate shift shaft and shift lever/blockout bush
ing assembly until roll pin holes are aligned and
horizontal.
• Support shift shaft while intalling roll pin.
• Install pin until flush with the shift lever.
25. Detent spring and ball plunger into hole in the shift
lever (figure 31).
• Rotate shift shaft counter-clockwise until shift
lever is almost into fifth-reverse insert notch.
• Install spring and plunger into shift lever.
• Rotate shift shaft until shift lever aligns with 3-4
insert. 31. Two dowels.
26. Shift socket to shift shaft roll pin (figure 31). 32. Bolts (figure 10).
• Align holes in the shift socket and shift shaft. • Do not tighten.
• Drive roll pin until it is flush with the bottom of • Tip vertically.
the shift socket.
33. NEW snap ring (figure 9).
Important • It may be necessary to pull out on the input
shaft to install the snap ring.
• Use the second (middle) roll pin hole on the • Apply gasket maker GM P/N 1052943 or equiv
MG5 and transmission and the rear roll pin hole alent to the inside of the bolt hole pattern.
on the M50 transmission.
• Excessive force will "peen" the shift shaft and
damage the rear housing shift shaft bearing
causing increased shift effort. • DO NOT APPLY too much gasket maker
27. Gasket maker GM P/N 1052943 or equivalent to around the oil drain back hole. This could clog
both sides of the plate and install to case opening. the hole causing a low fluid flow through the
• Thin side of plate as viewed from the top bearing resulting in premature bearing failure.
should be installed towards the left side of the 34. Input shaft bearing retainer assembly and six bolts.
transmission. • Make sure oil drain back hole is lined up with
28. Shift tower and bolts (figure 32). the hole in the housing.
£ 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.
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
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
Capacity.................................................................................................................................................................1.98L (2.0 qts.)
Type Recommended............................................................................................................Synchromesh Transmission Fluid
T3157
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 8433 J 26941 J 36503

6. 12 . 18.
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
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
20. SHIFT SHAFT DETENT BUSHING REMOVER/INSTALLER

21. SHIFT SHAFT DETENT PLUG REMOVER
22. CLUTCH FORK PIVOT REMOVER/INSTALLER
23. OIL FILL/DRAIN PLUG HEX BIT (17 MM)
24. GEAR AND BEARING SEPARATOR PLATE
25. ASSEMBLY PALLET WITH COUNTER SHAFT ADAPTER
26. 2WD OUTPUT SHAFT BEARING RETAINER ALIGNMENT CABLES
27. SHIFT RAIL BUSHING INSTALLING AND STACKING TOOL
28. SHIFT RAIL BUSHING REMOVER
29. TRANSMISSION HOLDING REMOVER
30. 4WD OUTPUT SHAFT OIL SEAL REMOVER
31. REVERSE DRAG SEAL INSTALLER
32. OVERDRIVE DRAG SEAL INSTALLER
NOTES
. 4
-v •
1*. ’ • ,■ .
'■ .. -'v"*:
'■ - ' -2t, ■■'- -
■
, ‘v -
-r;
•, > -'•*.*;» . f . ,
. . .. „
t- ■ ■ . *. .
-
...... ..t f .,v, .
:s ■ ftme
NEW VENTURE GEAR 4500 MANUAL TRANSMISSION 7B8-1
SECTION 7B8
NEW VENTURE GEAR 4500

MANUAL TRANSMISSION
be used. Fasteners that are n ot reused, and those requiring thread locking com pound will b e called out.
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
Fastener Tightening Specifications.................................................................................................................. 7B8-12
Lubrication Specifications............................. ..................................................................................................... 7B8-12
Special Tools............................................................................................................................................................. 7B8-13
UNIT DISASSEMBLY
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
Figure 8—Fifth Gear Components Figure 11—Reverse idler Gear Shaft Removal
Figure 9— Mainshaft Fifth Gear Removal

Figure 12—Countershaft Rear Bearing Removal
9. Rear oil retainer from the transmission case (figure 3).

• It may be necessary to use a soft-faced ham
mer to separate the rear oil retainer from the
transmission case.
• Move synchronizer sleeves to lock transmission
into two gears at once.
10. Mainshaft nut and washer, using J 38805 (figure 4)
(4WD models only).
11. Vibration damper (figure 5) (4WD models only).
12. Main drive gear bearing retainer bolts.
13. Main drive gear bearing retainer (figure 6).
• Mark the retainer and the case for alignment.
• Drive the bearing retainer from the transmission
case by inserting a brass punch in the slot pro
vided.
14. Main drive gear and main drive gear bearing (figure
7).
15. Fifth gear shift fork roll pins.
• Support the fifth gear fork and drive the pins out
Figure 10— Mainshaft Assembly
from the bottom of the fork
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.
DISASSEMBLY AND ASSEMBLY OF

SUB-ASSEMBLIES
MAIN DRIVE GEAR 4. Third gear and synchronizer assembly (figure 15).
• Attach a two-jaw puller to the clutch gear of the
* Disassemble third gear. Remove the synchronizer assembly,
synchronizer ring, and third speed gear togeth
1. Pilot bearing. er.
2. Bearing using suitable puller.
5. Third gear bearing (figure 16).
Clean 6. Third gear bearing spacer (figure 16).
7. Second gear thrust washer snap ring (figure 17).
8. Second gear thrust washer (figure 17).
All parts in a suitable solvent.
9. Second gear thrust washer retaining pin (figure 17).
Important 10. Second gear (figure 18).
11. Second gear bearing (figure 19).
Do not spin dry the bearings.
I? Inspect
Parts for damage and wear.

Lubricate the bearings with Castrol Syntorq LT
transmission fluid and check for roughness.
Assemble (Figure 13)
Tool Required:
J 22828 Main Drive Gear Bearing Installer
1. Bearing using J 22828 (figure 13).
2. Pilot bearing.
MAINSHAFT
1. Fourth gear clutch gear.

2. Main drive gear thrust bearing (figure 14).
3. Fourth gear synchronizer ring.
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).
Figure 18—Second Gear Figure 20—Second Gear Synchronizer Ring Snap

Ring
Figure 19—Second Gear Bearing

Figure 21 —Second Gear Synchronizer Rings
Assemble (Figures 14 through 25 and 27
through 30) 10. First gear synchronizer rings (figure 25).
11. First gear synchronizer ring snap ring (figure 24).
1. First gear bearing and first gear (figure 30). 12. 1-2 synchronizer assembly to the mainshaft (figure
2. Reverse gear clutch gear and synchronizer ring. 23).
3. Reverse gear clutch gear snap ring.
4. Reverse bearing spacer and bearing (figure 29). • Synchronizer assembly must be installed with
5. Reverse gear and synchronizer assembly to the the taper side of the synchronizer sleeve
mainshaft. Rotate assembly until gear drops into towards second gear.
the fully seated position (figure 28). 13. 1-2 synchronizer assembly snap ring (figure 22).
• If the synchronizer assembly was disassem 14. Second gear synchronizer rings (figure 21).
bled, the synchronizer sleeve must be rein 15. Second gear synchronizer ring snap ring (figure
stalled with the taper towards the reverse gear. 20).
16. Second gear bearing (figure 19).
6. Reverse gear thrust washer (figure 27). 17. Second gear to the mainshaft (figure 18).
7. Rear mainshaft bearing using J 22828 and a press. 18. Second gear thrust washer retaining pin (figure 17).
19. Second gear thrust washer. Be sure the thrust
• Turn the mainshaft over.
washer is seated on the gear and retaining pin
8. First gear clutch gear. (figure 17).
9. First gear clutch gear snap ring. 20. Second gear thrust washer snap ring (figure 17).
21. Third gear bearing spacer to the mainshaft (figure COUNTERSHAFT

16).
22. Third gear bearing to the mainshaft (figure 16).
Important
23. Third speed gear and synchronizer assembly (fig
ure 15).
24. Main drive gear thrust bearing (figure 14). • Do not disassemble the countershaft. Individual
25. Fourth gear synchronizer ring. components of the countershaft are not serviced. If
26. Fourth gear clutch gear. the countershaft is damaged or worn, it must be
replaced as a complete assembly.
Figure 26— Rear Mainshaft Bearing Removal Figure 28— Reverse Gear
Figure 27—Reverse Gear Thrust Washer Figure 29— Reverse Gear Bearing and Spacer
REAR OIL RETAINER SEAL REPLACEMENT (2WD MODELS)

EXTENSION HOUSING ++ Remove or Disconnect
BEARING REPLACEMENT (2WD MODELS)
1. Oil seal from the extension housing.
. Qnhsoc .i •' •"
Remove or Disconnect • Pry the seal out with a small pry bar or equiva
lent.
1. Extension oil seal. Refer to “Seal Replacement.” • Inspect the retainer for damage.
2. Extension housing bearing snap ring.
3. Bearing from the extension housing. +<- Install or Connect (Figures 31, and 32)
+«- Install or Connect

Tool Required:
J 22834 Extension Housing Seal Installer
Tool Required:
J 38807 Extension Housing Bearing Installer 1. New seal into the extension housing using J 22834
(figures 31 and 32).
1. Bearing into the extension housing using J 38807.
2. Extension housing bearing snap ring.
3. Extension oil seal. Refer to “Seal Replacement.”
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
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.
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
• Countershaft bearing retainer bolts to 35 N-m

(26 lbs. ft.).
Figure 35—Countershaft Rear Bearing Installation
J 38856
Figure 34—Countershaft Front Bearing Cup

Installation Figure 36—Checking Countershaft End play
NEW VENTURE GEAR 4500 MANUAL TRANSMISSION 7B 8-11
13. Mainshaft assembly into the transmission case (fig

ure 10).
14. Mainshaft rear bearing cup, shim(s), and retainer
plate.
15. Mainshaft bearing retainer plate bolts.
• Finger tighten only.
16. Countershaft thrust washer retainer pin and coun
tershaft thrust washer.
17. Fifth gear bearings and spacer onto the counter
shaft.
18. Fifth gear assembly onto the fifth shift rail and the
countershaft.
• Slide fifth gear fork and fifth gear assembly onto
the shift rail.
19. Fifth gear clutch gear snap ring.
20. Fifth gear shift fork roll pins.
• Support the overdrive fork and drive the roll
pins downward from the top of the fork.
21. Main drive gear bearing and drive gear into the
transmission case (figure 7).
Figure 37—Countershaft Bearing Cap Installation
22. Main drive gear bearing retainer (figure 6).
• Position retainer with oil hole at the top-center
position.
• Apply GM P/N 1052942 or the equivalent seal
ant.
• Use care not to seal off oil hole.
23. Main drive gear retainer bolts.
Tighten
• Main drive gear retainer bolts to 31 N-m (23 lbs.

ft.).
• Mainshaft bearing retainer plate bolts to 35 N-m
(26 lbs. ft.).
* Measure
• Mainshaft end play (figure 38).

A. Set the dial indicator up on the end of the main
shaft.
B. Use screwdriver or equivalent to lift mainshaft
up and down to measure end play.
Figure 38—Checking Mainshaft End Play C. Mainshaft end play should be 0.05-0.15 mm
(0.002-0.006 in.).Adjust by adding or removing
shim(s) under mainshaft bearing retainer plate.
D. Remove bolts and apply Loctite® Dri-Loc 201
or equivalent to the bolts and retorque.
24. Vibration damper to the mainshaft using J 39314
(figure 39) (4WD models only).
• Move synchronizer sleeves to lock transmission
into two gears at once.
25. Mainshaft washer and nut using J 38805 (figure 4)
(4WD models only).
& Tighten
• Mainshaft nut to 441 N-m (325 lbs. ft.).

26. Rear oil retainer to the transmission case (figure 3).
27. Rear oil retainer to the transmission case bolts.
$ Tighten
• Rear oil retainer bolts to 54 N-m (40 lbs. ft.).

28. Yoke assembly (2WD models only).
Figure 39—Vibration Damper Installation (4WD 29. Spline seal, washer, and a new nut (2WD models
Models) only).
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
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
Capacity................................................................................................................................................................. 3.78L (8 Pints)
Type Recommended.................................................................................................. Castrol Syntorq LT Transmission Fluid
T2860
SPECIAL TOOLS
J 22828 J 38807
J 38856
J 22834
J 38801 J 39314
4. J 38805
1. INPUT SHAFT BEARING INSTALLER/COUNTERSHAFT BEARING CONE INSTALLER

2. EXTENSION HOUSING SEAL INSTALLER (2WD MODELS)
3. INPUT SHAFT SEAL INSTALLER
4. OUTPUT SHAFT NUT SOCKET (4WD MODELS)
5. EXTENSION HOUSING BEARING INSTALLER (2WD MODELS)
6. COUNTERSHAFT BEARING CUP AND RETAINER INSTALLER
7. VIBRATION DAMPER INS1ALLER (4WD MODELS) 3707r5173
NOTES
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NEW PROCESS 233 TRANSFER CASE 7D1-1
SECTION 7D
TRANSFER CASE
CONTENTS
SUBJECT PAGE
SECTION 7D1
NEW PROCESS 233 TRANSFER CASE

are not followed, parts or system dam age could result.
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
Figure 1—Rear Housing and Components

Figure 2—Front Housing and Components
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).
Figure 3—Encoder Motor Figure 5—Vehicle Speed Sensor
Figure 4—Vacuum Switch Figure 6—Detent Plug, Spring, and Plunger
• 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.
Figure 7—Extension Housing Figure 9— Rear Retainer Housing
Figure 8— Rear Bearing Retainer Snap Ring Figure 10—Vehicle Speed Sensor Rotor Snap Ring
• Be careful not to damage the oil pump (located | V | Important

in the rear case half) while removing the rear
case half. The annulus gear found in this transfer case is not
serviceable or removable, and should only be replaced
INTERNAL COMPONENTS as a unit with the front case half. If the annulus gear is
removed, damage will result to the case.
++ Remove or Disconnect (Figures 14 through 1. Oil pump from the pickup tube and rear case half
(figure 14).
31) 2. Oil pump pickup tube, O-ring, and pump pickup
filter from the rear case half (figure 15).
Tools Required: 3. Mode fork shift spring and washer from the shift rail
J 8092 Driver Handle (figure 16).
J 36370 Bearing Installer/Remover 4. Front output shaft seal from the front case half.
J 29170 Bearing Remover 5. Front output shaft snap ring (figure 17).
J 29369-1 Bearing Remover 6. Mainshaft, drive chain, and driven sprocket from
J 9276-21 Adapter the front case half as an assembly (figure 18).
J 2619-01 Slide Hammer • Mode shift fork and shift rail will be removed
J 33790 Bearing Remover with the mainshaft.
7. Synchronizer to mainshaft snap ring (figure 19).
Ring
8. Synchronizer assembly from the mainshaft (figure

20).
9. Drive sprocket from the mainshaft.
10. Range shift fork assembly and range shift hub from
the planetary carrier (figure 21).
• It is necessary to rotate the sector shaft to
obtain clearance when removing the range fork.
11. Shift sector snap ring, plastic washer, sector shaft
assembly, and O-ring from the front case half (fig
ures 22 and 23).
12. Input bearing retainer bolts and input bearing
retainer from the front case half (figure 24).
13. Input gear snap ring (figure 25).
14. Input and low range gear assembly from the annu-
lus gear using a soft faced hammer (figure 26).
15. Input gear to the low range gear assembly snap
ring (figure 27).
16. Input gear from the low range gear assembly.
Figure 16— Mode Fork Shift Spring Figure 18— Drive Chain, Mainshaft, and Driven
Sprocket
Figure 17— Front Output Shaft Snap Ring

Figure 19—Synchronizer to Mainshaft Snap Ring
17. Input bearing from the front case half using
J 36370 and J 8092. 1. Main drive synchronizer stop ring from the synchro
18. Needle bearings from the input gear using nizer sleeve (figure 32).
J 29369-1, J 9276-21 and J 2619-01 (figure 28). 2. Spring retainers from the synchronizer hub.
19. Front output bearing snap ring (figure 29). 3. Synchronizer hub from the synchronizer.
20. Front output bearing from the front case half using 4. Oil pump screws from the oil pump.
J 33790 and J 8092.
21. Seal from the mainshaft extension housing. Important
22. Seal from the input bearing retainer.
23. Front output rear bearing from the rear case half The oil pump is not a serviceable unit and should be
using J 2619-01 and J 29369-2 (figure 30). replaced if it is defective.
24. Mainshaft bearing from the oil pump retainer using
J 33790.
25. Magnet from the front case half (figure 31).
• Mark the location of the synchronizer hub and

sleeve to aid in assembly. Synchronizer teeth must
align with struts.
Figure 20—Synchronizer Assembly Figure 23—Sector Shaft Assembly
Figure 22—Sector Shaft Snap Ring Figure 25—Input Gear Snap Ring
Figure 28—Input Gear Bearing Removal

Figure 32—Synchronizer Components

| Clean 3. Gear splines for excessive wear, spalling, cracks,
twist, or corrosion.
Bearings. 4. Shaft splines for excessive wear, spalling, cracks,
• Remove all old lubricant and dirt. distortion, or corrosion.
Shafts. 5. Retainer rings for excessive wear, distortion or
Sprockets. damage.
Chain. 6. Case halves for damaged or warped mating sur
Oil feed ports and channels in each case half. faces, cracks, porosity, or damaged thread holes.
Apply compressed air to each oil feed port and 7. Synchronizer stop rings for cracks, chips, spalling,
channel to remove any obstructions, or cleaning or excessive wear.
solvent residue. 8. Synchronizer hub and sleeve for cracks, chips,
All mating and sealing surfaces. spalling, or excessive wear.
Inspect 9. Pads on mode fork and range fork for wear and
distortion.
10. Oil pump gears and case halves for wear, spalling,
1. Bearings and thrust washers for spalling, brinnel- cracks, and damage. Replace complete assembly
ing, or corrosion. if there is wear.
2. Gear teeth for excessive wear or damage, spalling, 11. Input gear, planetary carrier, and range shift hub
cracks, or corrosion. tooth chamfers for excessive wear.
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.
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).
— ■ -I-
4. Shift sector with shaft, O-ring seal, plastic washer,

and snap ring into the front case half (figures 22
and 23).
5. Range shift hub and range shift fork into the front
case half (figure 21).
• It is necessary to rotate the sector to align the
range shift fork.
6. Chain over main shaft onto drive gear (figure 18).
• Install mainshaft assembly, chain and front out
put shaft into case as an assembly.
7. Mainshaft assembly, mode shift fork, and rail
through range shift fork into front case half (figure
18).
8. Front output shaft into chain and into front case
half.
9. Fork shift spring onto the mode shift rail (figure 16).
10. Oil pickup tube, oil tube connector, and pump pick
up screen into the rear case half (figure 15).
11. Oil tube O-ring onto the oil pump pickup tube.
Installation
NOTICE: Do n ot dam age the O-ring during
8. Input gear to the planetary carrier snap ring (figure assem b ly as this could result in pum p failure.
27).
9. Bearing into front case half using J 36372. 12. Oil pump to the oil pump pickup tube (figure 14).
10. Oil seal into the rear extension using J 33843.
11. Input bearing retainer seal into the input bearing • Apply RTV sealer (GM P/N 12345739) or the
retainer using J 33831. equivalent to the case mating surfaces.
12. Magnet into front case half (figure 31). 13. Rear case over mainshaft and onto the front case
half.
INTERNAL COMPONENTS
• Be careful not to damage the oil pump when
Assemble (Figures 19, 20, and 32) installing the case halves together.
14. Case bolts into case halves.
1. Synchronizer hub to the synchronizer sleeve along
with the three struts (figure 32). •A pply threadlocker (GM P/N 12345382) or
• Align the scribe marks. equivalent to the case bolts.
2. Spring retainers to the synchronizer hub (figure • The two longer case bolts and washers into the
32). doweled case holes, or from their original holes
3. Main drive synchronizer stop ring to the synchro on transfer cases with attaching brackets.
nizer sleeve and the synchronizer hub.
4. Drive sprocket to mainshaft (figure 20).
Tighten
5. Synchronizer assembly to mainshaft (figure 20).
6. Synchronizer to the mainshaft snap ring (figure 19). • Case bolts to 31 N-m (23 lbs. ft.).
15. Snap ring to the mainshaft (figure 12).
Install or Connect (Figures 7, 8, 10, 11, 12, 14, 16. Vehicle speed sensor rotor onto mainshaft (figure
15, 16, 18, 21, 22, 23, 25, and 26) 11).
17. Vehicle speed sensor rotor snap ring (figure 10).
1. Planetary input gear assembly through the input 18. Rear retainer housing and rear retainer housing
bearing into the annulus using a soft faced hammer bolts to the rear case half.
(figure 26).
•A pply threadlocker (GM P/N 12345382) or
equivalent to the rear retainer housing bolt
3. Input bearing retainer and input bearing retainer
threads.
bolts to front case half.
•Apply RTV (GM P/N 12345739) or the equiva
• Apply RTV (GM P/N 12345739) or the equiva
lent at the joint.
lent on bearing retainer mating surfaces.
•Apply threadlocker (GM P/N 12345382) or the Tighten
equivalent to bearing retainer bolts.
Rear retainer housing bolts to 41 N-m (30 lbs.
ft.).
• Input bearing retainer bolts to 19 N-m (14 lbs. 19. Rear bearing retainer snap ring to the mainshaft
ft.). (figure 8).
20. Rear extension housing and extension housing

bolts to the rear retainer housing (figure 7).
•Apply RTV sealer (GM P/N 12345739) to the
extension housing mating surfaces.
equivalent to the extension housing bolts.
$ Tighten
EXTERNAL COMPONENTS
0 Install or Connect (Figures 3 through 6)
1. Detent plunger, detent spring, O-ring seal, and

detent plug into front case half (figure 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
Tighten • Encoder motor bolts to 18 N-m (13 lbs. ft.).

$
5. Snap ring.
• Vehicle speed sensor to 31 N-m (23 lbs. ft.). 6. Front output shaft seal into the front case half
3. Vacuum switch and O-ring to the front case hous
7. Yoke seal over front output shaft.
ing (figure 4).
8. Snap ring on front output shaft.
Tighten
• Switch to 24 N-m (17 lbs. ft.).
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
Capacity.............................................................................................................................................................. 1.18L (1.25 qts.)
Type Recommended............................................................................................Dexron® III Automatic Transmission Fluid
T2865
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
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NEW PROCESS 241 TRANSFER CASE 7D2*1
SECTION 7D2
NEW PROCESS 241

TRANSFER CASE
CONTENTS
SUBJECT PAGE
Model 2 4 1 ............................................................................................................................................................... 7D2- 1
Power Flow ......................................................................................................................................................... 7D2- 1
Disassembly................................................................................................................................................................7D2- 2
Mainshaft Extension and Rear Retainer Housing......................................................................................... 7D2- 2
Cleaning and Inspection......................................................................................................................................... 7D2- 7
Assembly..................................................................................................................................................................... 7D2- 8
Bearing and Seal Replacement......................................................................................................................... 7D2- 8
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.
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.
1. Front output yoke nut, washer, rubber sealing

washer, and front output yoke from the front output
shaft.
2. Four-wheel drive actuator switch and O-ring seal.
3. Vehicle speed sensor and O-ring seal (figure 1).
4. Detent plug, O-ring seal, detent spring, and detent
plunger (figure 2).
MAINSHAFT EXTENSION AND

REAR RETAINER HOUSING
1. Rear extension housing bolts and rear extension

(figure 3).
2. Rear bearing retainer snap ring from the mainshaft
(figure 4). Figure 2—Detent Plug, Spring, and Plunger
Figure 1—Vehicle Speed Sensor Figure 3—Extension Housing

Figure 6—Vehicle Speed Sensor Rotor Snap Ring Figure 9— Front and Rear 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).
• Separate the case halves by inserting two screw
15).
drivers into the slots cast into the case ends and
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 22912-1 Bearing Remover
J 29369-1 Output Shaft Bearing Remover
J 9276-21 Slide Hammer Adapter
J 33832 Bearing Installer/Remover
NOTICE:The annulus gear found in this trans

fer case is not serviceable or removable and
should only be replaced as a unit with the
fr o n t c a s e half. If th e a n n u lu s g e a r is
removed, damage to the case will result. Figure 11—Oil Pump Pickup Tube and Filter
Figure 10—Oil Pump Figure 12—Mode Fork Shift Spring

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).
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 17—Shift Sector Assembly

Figure 18— Removing Front Bearing Retainer Figure 21—Input and Low Gear Assembly
Figure 22—Input Gear
Figure 23—Input Gear Bearing Removal

Figure 20—Input Bearing Snap Ring
Figure 26—Synchronizer Components
21. Front output bearing from front case half using

J 33832 and J 8092.
22. Seal from the mainshaft extension housing.
23. Seal from input bearing retainer.
24. Front output rear bearing from rear case half (figure
24).
25. Mainshaft bearing from the rear retainer housing.
26. Magnet from the front case half (figure 25).
Important
• Scribe the location of the synchronizer sleeve

and hub to aid in assembly.
1. Main drive synchronizer stop ring from the synchro
nizer sleeve.
2. Spring retainers from the synchronizer hub.
3. Synchronizer hub from the synchronizer sleeve.
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.

SB Clean L9 Inspect
1. Bearings. 1. Bearings and thrust washers for spalling, brinnel-

• Remove all old lubricant and dirt. ing, or corrosion.
2. Shafts. 2. Gear teeth for excessive wear or damage, spalling,
3. Sprockets. cracks, or corrosion.
4. Chain. 3. Gear splines for excessive wear, spalling, cracks,
5. Oil feed ports and channels in each case half. twist, or corrosion.
Apply compressed air to each oil feed port and 4. Shaft splines for excessive wear, spalling, cracks,
channel to remove any obstructions or cleaning distortion, or corrosion.
solvent residue. 5. Retainer rings for excessive wear, distortion, or
6. All mating and sealing surfaces damage.
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
+«* Install or Connect 1 Tighten
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 assembly, driven sprocket, and drive
chain are installed into the front case half as an
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.).
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
Capacity.................................................................................................................................................................2.13L (4.5 pts.)
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
SECTION 7D3
NEW PROCESS 231

TRANSFER CASE
NOTICE: When fasteners are rem oved , always reinstall them at the sam e location from which they were
removed. If a fastener n eed s to be replaced, use the correct part num ber fastener for that application. If
CONTENTS
SUBJECT PAGE
Model 2 3 1 ............................................................................................................................................................... 7D3- 1
Power Flow ......................................................................................................................................................... 7D3- 1
Disassembly............................................................................................................................................................... 7D3- 3
Mainshaft Extension and Rear Retainer Housing......................................................................................... 7D3- 3
Cleaning and Inspection......................................................................................................................................... 7D3-10
Assembly.....................................................................................................................................................................7D3-10
Bearing and Seal Replacement......................................................................................................................... 7D3-10
Internal Components............................................................................................................................................ 7D3-11
External Components........................................................................................................................................... 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
Figure 1—Front Case and Components

sprocket to the mainshaft through the synchronizer. In 4LO range, the path of torque through the transfer
Torque is transmitted through the drive sprocket to the case is exactly the same as in 4HI range but with one
driven sprocket by the connecting drive chain. Since the major difference. In 4LO range, the range shift hub is
front output shaft is splined to the driven sprocket, shifted into engagement with the planetary carrier. This
torque flows through the front output shaft to the front causes the input gear to rotate the planetary pinions
propeller shaft and axle resulting in high range inside the annulus gear, causing the planetary carrier,
four-wheel drive. range shift hub and mainshaft to rotate at a gear reduc
tion ratio of 2.72:1.
——
Figure 2—Rear Case and Components
DISASSEMBLY
EXTERNAL COMPONENTS MAINSHAFT EXTENSION AND
REAR RETAINER HOUSING
Clean
• 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.
Figure 3—Vehicle Speed Sensor Figure 6—Extension Housing
Figure 4—Vacuum Switch

Figure 7—Rear Bearing Retainer Snap Ring
4. Rear retainer housing from the rear case half (fig

ure 8).
• Carefully pry upward under each tab on retainer
housing.
Important
• Do not pry against the sealing surfaces of the

rear retainer or rear case. Only pry under tabs
on retainer housing.
5. Vehicle speed sensor rotor snap ring from the
6. Vehicle speed sensor rotor from the mainshaft (fig
ure 10).
7. Snap ring from the mainshaft (figure 11).
8. Case bolts from the case halves.
Figure 5— Detent Plug, Spring, and Plunger • Note: The two longer case bolts and washers
go into the doweled case holes.
Figure 8—Rear Retainer Housing Figure 11—Rear Vehicle Speed Sensor Rotor Snap
Ring
Figure 9—Vehicle Speed Sensor Rotor Snap Ring

Figure 12—Front and Rear Case
V Important
• Some transfer case models have a bracket

attached to them by the case half bolts. These
bolts are different from the others and must be
put back into the correct holes.
9. Rear case half and oil pump as an assembly from
the front case (figure 12).
• Separate the case halves by inserting screw
drivers into the slots cast into the case ends
and pry apart. Do not attempt to wedge the
case halves apart at any point on the mating
surfaces. Damage to the case may result.
• Be careful not to damage the oil pump (located
in the rear case half) while removing the rear
case half.
Figure 10—Vehicle Speed Sensor Rotor
Figure 13—Oil Pump Figure 15—Mode Fork Shift Spring
Figure 14—Oil Pump Pickup Tube and Screen
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
the front case half as an assembly (figure 17).
J 29369-1 Bearing Remover • Mode shift fork and shift rail will be removed
J 9276-21 Adapter with the mainshaft.
7. Synchronizer to mainshaft snap ring (figure 18).
19).
Important
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.
Figure 17— Drive Chain, Mainshaft, and Driven Figure 19—Synchronizer Assembly
Sprocket
Figure 20—Range Shift Fork and Range Shift Hub

Figure 18—Synchronizer to Mainshaft Snap Ring
23. Front output rear bearing from the rear case half
11. Shift lever nut, washer, shift lever, sector and shaft using J 2619-01 and J 29369-2 (figure 28).
assembly, plastic washer, and the O-ring seal from 24. Mainshaft bearing from the oil pump retainer using
the front case half (figure 21). J 33790.
12. Input bearing retainer bolts and input bearing 25. Magnet from the front case half (figure 29).
retainer from the front case half (figure 22).
13. Input gear snap ring (figure 23). * Disassemble (Figure 30)
14. Input and low range gear assembly from the annu
lus gear using a soft faced hammer (figure 24). • Mark the location of the synchronizer hub and
15. Input gear to the low range gear assembly snap sleeve to aid in assembly. Synchronizer teeth must
ring (figure 25). align with struts.
16. Input gear from the low range gear assembly. 1. Main drive synchronizer stop ring from the synchro
17. Input bearing from the front case half using nizer sleeve (figure 30).
J 36370 and J 8092. 2. Spring retainers from the synchronizer hub.
18. Needle bearings from the input gear using 3. Synchronizer hub from the synchronizer.
J 29369-1, J 9276-21 and J 2619-01 (figure 26). 4. Oil pump screws from the oil pump.
19. Front output bearing snap ring (figure 27).
20. Front output bearing from the front case half using Important
J 33790 and J 8092.
21. Seal from the mainshaft extension housing. The oil pump is not a serviceable unit and should be
22. Seal from the input bearing retainer. replaced if it is defective.
Figure 22— Removing Front Bearing Retainer Figure 24—Input and Low Range Gear Assembly
Figure 25— Input Gear Figure 27—Front Output Bearing Snap Ring
Figure 26— Input Gear Bearing Removal Figure 28—Front Output Rear Bearing Removal
Figure 29—Magnet Figure 30—Synchronizer Components

J \ Clean 3. Gear splines for excessive wear, spalling, cracks,
twist, or corrosion.
1. Bearings. 4. Shaft splines for excessive wear, spalling, cracks,
• Remove all old lubricant and dirt. distortion, or corrosion.
2. Shafts. 5. Retainer rings for excessive wear, distortion or
3. Sprockets. damage.
4. Chain. 6. Case halves for damaged or warped mating sur
5. Oil feed ports and channels in each case half. faces, cracks, porosity, or damaged thread holes.
Apply compressed air to each oil feed port and 7. Synchronizer stop rings for cracks, chips, spalling,
channel to remove any obstructions, or cleaning or excessive wear.
solvent residue. 8. Synchronizer hub and sleeve for cracks, chips,
6. All mating and sealing surfaces. spalling, or excessive wear.
9. Pads on mode fork and range fork for wear and
I? Inspect
distortion.
10. Oil pump gears and case halves for wear, spalling,
1. Bearings and thrust washers for spalling, brinnel-
ing, or corrosion. cracks, and damage. Replace complete assembly
2. Gear teeth for excessive wear or damage, spalling, if there is wear.
cracks, or corrosion. 11. Input gear, planetary carrier, and range shift hub
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).
8. Input gear to the planetary carrier snap ring (figure

25).
9. Bearing into front case half using J 36372.
10. Oil seal into the rear extension using J 33843.
11. Input bearing retainer seal into the input bearing
retainer using J 33831.
12. Magnet into front case half (figure 29).
INTERNAL COMPONENTS
1. Synchronizer hub to the synchronizer sleeve along

with the three struts (figure 30).
• Align the scribe marks.
2. Spring retainers to the synchronizer hub (figure
30).
3. Main drive synchronizer stop ring to the synchro
nizer sleeve and the synchronizer hub.
4. Drive sprocket to mainshaft (figure 19).
5. Synchronizer assembly to mainshaft (figure 19).
6. Synchronizer to the mainshaft snap ring (figure 18). Installation
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)-
21. Rear extension housing and extension housing

bolts to the rear retainer housing (figure 6).
•Apply RTV sealer (GM P/N 12345739) to the
extension housing mating surfaces.
equivalent to the extension housing bolts.
Tighten
EXTERNAL COMPONENTS
++ Install or Connect (Figures 3 through 5)

detent plug into front case half (figure 5).
& Tighten
• Detent plug to housing to 15 N m (11 lbs. ft.).

2. Vehicle speed sensor and O-ring to the rear hous
ing (figure 3).
4. Snap ring.
Tighten 5. Front output shaft seal into the front case half
• Vehicle speed sensor to 31 N-m (23 lbs. ft.). 6. Yoke seal over front output shaft.
3. Vacuum switch and O-ring to the front case hous 7. Snap ring on front output shaft.
ing (figure 4). 8. Shift lever.
9. Washer and nut.
Tighten
• Vacuum switch to 24 N-m (17 lbs. ft.).
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
Capacity.................... ............................................1.18L (1.25 qts.)
Type Recommended Dexron® III Automatic Transmission Fluid
T2541
SPECIAL TOOLS
1. SLIDE HAMMER
2. DRIVER HANDLE 8. BEARING INSTALLER
3. BEARING REMOVER 9. BEARING INSTALLER
5. OUTPUT SHAFT BEARING REMOVER 11. EXTENSION HOUSING SEAL INSTALLER
6. ADAPTER 12. BEARING INSTALLER
7. BEARING INSTALLER 13. BEARING REMOVER
V2831
NOTES
'
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-r r -s r y r
',v. o w X S a ' i
j v 1S 3 / J
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h mj s\-
r, :
BORG-WARNER 4401 TRANSFER CASE 7D4-1
SECTION 7D4
BORG-WARNER 4401
TRANSFER CASE
CONTENTS
SUBJECT PAGE
4401 Transfer Case................................................................................................................................................7D4- 1
Power Flow ......................................................................................................................................................... 7D4- 1
Disassembly............................................................................................................................................................... 7D4- 2
Synchronizer Hub Assembly.............................................................................................................................. 7D4- 4
Oil Pump Assembly.............................................................................................................................................. 7D4- 4
Assembly.....................................................................................................................................................................7D4- 7
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
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
B
Tools Required:
J 22912-01 Gear Puller
J 8433-4 Puller
J 29169 Bearing Remover/Installer
J 33832 Bearing Remover/Installer Figure 2—Speedometer Tone Wheel Removal
8059
Figure 1—Rear Output Yoke Figure 3—Output Bearing Snap Ring

Figure 4—Clutch Coil Figure 6—Shift Mode Fork and the Synchronizer
Assembly
4. Case screws from the case halves. Note these are

14. Drive gear, driven gear, and drive chain as an
self-tapping screws and aluminum shavings are
assembly (figure 8).
common upon removal.
5. Rear case half from the front case half. 15. Front output shaft from the front output bearing.
16. Mainshaft and oil pump assembly from the input
• Using a suitable tool pry between the two pry
carrier assembly (figure 9).
bosses to separate the case halves.
17. Shift rail, range fork, and shift hub from the input
6. Clutch coil wire connector from the clutch coil wire carrier assembly (figure 10).
(figure 4).
18. Annulus gear snap ring from the front case (figure
7. Clutch coil nuts from the clutch coil assembly (fig
11).
ure 4).
19. Annulus gear from the front case (figure 12).
8. Clutch coil from the rear case half.
20. Input shaft oil seal from the front case.
9. Shift rail spring from the shift rail.
10. Clutch coil housing snap ring and the clutch coil 21. Carrier assembly snap ring from the carrier assem
housing from the mainshaft using J 8095 (figure 5). bly input shaft (figure 13).
11. Synchronizer hub from the synchronizer assembly. 22. Input carrier assembly and power take off drive
12. Synchronizer assembly from the mainshaft drive gear from the front case (figure 14).
gear and mode shift fork from the shift rail (figure 23. Retaining clip from the sector shaft (figure 15).
6 ). 24. Sector shaft from the front case.
13. Front output shaft snap ring and flat washer from 25. Sector, detent spring, and detent roller from the
the front output shaft (figure 7). front case.
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.
Figure 12— Annulus Gear
2. Oil pump body and pickup tube assembly from the

mainshaft.
3. Oil pump pins and oil pump spring from the main
shaft.
4. Oil pump front cover from the mainshaft.
5. Clamp from the pickup tube.
6. Pickup tube and oil pump pickup from the oil pump
body.
7. Oil pump pickup from the pickup tube.
Figure 14— Input Carrier and PTO Gear

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

IJJI Clean 2. Gear teeth for excessive wear or damage, spalling,
cracks, or corrosion.
1. Bearings. 3. Gear splines for excessive wear, spalling, cracks,
2. Shafts. twist, or corrosion.
3. Sprockets. 4. Shaft splines for excessive wear, spalling, cracks,
4. Chain. distortion, or corrosion.
5. Oil feed ports and channels in each case half. 5. Retainer rings for excessive wear, distortion, or
Apply compressed air to each oil feed port and damage.
channel in order to remove any obstructions or 6. Case halves for damaged or warped mating sur
cleaning solvent residue. faces, cracks, porosity, or damaged thread holes.
6. All mating surfaces.
7. Synchronizer assembly for cracks chips, spalling,
or excessive wear.
L* Inspect
8. Synchronizer hub and sleeve for cracks, chips,
1. Bearings and thrust washers for wear, spalling, spalling, or excessive wear.
brinelling, or corrosion.
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.).
OIL PUMP ASSEMBLY JP Inspect
* 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
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
Figure 21—Synchronizer Hub Assembly Figure 22—Front Output Bearing Installation

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

3. Four-wheel drive indicator switch to the front case
half.
Tighten
• Sensor to 27.Nm (20 lbs. ft.).

4. Speed sensor and bolt to the rear bearing retainer.
Tighten
• Bolt to 16 N.m (12 lbs. ft.).

5. Rear output yoke, rubber sealing washer, flat wash
er, and the rear output yoke nut to the rear output
shaft (figure 1).
Tighten
• Nut to 170 N.m (125 lbs. ft.). * Nut t0 224 N m (165 lbs- ft-)-
6. Front output yoke, rubber sealing washer, flat

washer, and the front output yoke nut to the front
output shaft.
SPECIFICATIONS
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 —
Capacity...................................................................................................................................................................1.5L (1.6 qts.)
Type Recommended.................................................................... Dexron® III Automatic Transmission Fluidor equivalent
T2542
SPECIAL TOOLS
J 22912-01 J 8092
J 8433-4 8. J 5590
9. J 29369-1
3. J8059
4. J 29169 10. J 2619-01
5. J 33832
1. Bearing and Gear Puller
2. Puller
3. Snap Ring Pliers
4. Bearing Remover/Installer
6. J 37668 6. Seal Installer
7. Driver Handle
8. Installer
9. Output Shaft Bearing Remover
10. Slide Hammer
F7663
SECTION 7D5
BORG-WARNER 4472 TRANSFER CASE

be used. Fasteners that are n ot reused, and those requiring thread locking com pound will b e called out.
CONTENTS
SUBJECT PAGE
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
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.
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 ).
INTERNAL COMPONENTS
1. Front output flange nut, steel flat washer, and rub
ber sealing washer from the front output shaft (fig
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).
Figure 2—Separating Case Figure 4— Drive Chain

3. Magnet from the rear case half.

4. Input shaft from the sun gear shaft (figure 5).
5. Sun gear shaft, sun gear shaft bearing, drive
sprocket spacer, drive sprocket, and viscous clutch
as an assembly, from the planet carrier assembly
(figure 6).
6. Sun gear shaft thrust washer (figure 7).
7. Planet carrier assembly and the planet carrier
assembly thrust washer from the output shaft
8. Extension housing bolts from the extension hous
ing (figure 9).
9. Breather assembly from the extension housing.
10. Extension housing from the rear case half (figure
9).
•Turn the rear case half over and support the
output shaft assembly from the inside of the
rear case half.
Figure 7—Sun Gear Shaft Assembly Thrust Washer
Figure 8— Planet Carrier Assembly
Figure 6—Sun Gear Shaft Assembly Figure 9—Extension Housing

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
Fiqure 11—Ring Gear Snap Ring Figure 13—Front Housing Seals

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

Clean 2. Gear teeth for excessive wear or damage, spalling,
cracks, or corrosion.
1. Bearings. 3. Gear splines for excessive wear, spalling, cracks,
2. Shafts. twist, or corrosion.
3. Sprockets. 4. Shaft splines for excessive wear, spalling, cracks,
4. Chain. distortion, or corrosion.
5. Oil feed ports and channels. Apply compressed air 5. Case half for damaged or warped mating surfaces,
to each oil feed port and channel in order to cracks, porosity, or damaged thread holes.
remove any obstructions or cleaning solvent resi 6. Oil scoop on the output shaft assembly for cracks,
due. wear, or damage.
7. Speedometer tone wheel for wear, spalling, cracks,
L* Inspect
twist, and corrosion.
8. Speed sensor and the breather assembly O-ring
1. Bearings and thrust washers for wear, spalling,
brinelling, or corrosion. seals for cuts, tears, cracks, or damage.
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)
Assemble (Figures 11,12,14,17, 20 through 22) Tools Required:

1. Viscous clutch, drive sprocket, drive sprocket spac J 38216 Seal Installer
er, and the sun gear shaft bearing onto the sun 1. Output shaft assembly and ring gear through the
gear shaft (figure 17). rear case half.
2. Input shaft pilot bearing into the output shaft 2. Output shaft bearing snap ring to the output shaft
assembly using J 7079-2 and J 38212 (figure 20). bearing (figure 10).
3. Output shaft assembly to the ring gear (figure 12).
4. Ring gear snap ring to the ring gear (figure 11).
J 7 0 7 9 -2
J 38212
Figure 21—Front Output Shaft Front Bearing

Figure 20—Input Shaft Pilot Bearing Installation Installation
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).
• Extension housing bolts to 42 N-m (30 lbs. ft.). & Tighten j
5. Speed sensor and speed sensor bolt into the

Front output flange nut to 108 N-m (80 lbs. ft.).
extension housing.
SPECIFICATIONS
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 —
Capacity...................................................................................................................................................................1.2L (1.3 qts.)
T2380
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

2. PULLER 8. SEAL INSTALLER
3. SLIDE HAMMER 9 RTV
4. OUTPUT SHAFT BEARING REMOVER 10. FRONT OUTPUT SHAFT REAR BEARING REMOVER
5. DRIVER HANDLE 11. OUTPUT SHAFT BEARING INSTALLER
6. NEEDLE BEARING INSTALLER 12. DRIVER HANDLE
F7638
SECTION 7D6
BORG-WARNER 4470 TRANSFER CASE

NOTICE: When fasteners are r e m o v e d a lw a y s reinstall them at the sam e location from which they were
be used. Fasteners that are n o t reused, and those requiring thread locking com pound will be called out.
are not followed, parts or system dam age could result.
CONTENTS
SUBJECT PAGE
BW4470 Transfer Case......................................................................................................................................... 7D6- 1
Power Flow ......................................................................................................................................................... 7D6- 1
Disassembly............................................................................................................................................................... 7D6- 2
Oil Pump Assembly...............................................................................................................................................7D6- 5
Assembly.....................................................................................................................................................................7D6- 7
Synchronizer Assembly....................................................................................................................................... 7D6- 7
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
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
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
Tools Required:
J 22912-01 Gear Puller
J 8433-4 Puller
Figure 1—Rear Output Yoke Figure 3—Rear Output Bearing Snap Ring
Assembly
4. Case screws from the case halves. Note these are

self-tapping screws and aluminum shavings are 13. Front output shaft snap ring and flat washer from
common upon removal. the front output shaft (figure 7).
5. Rear case half from the front case half. 14. Drive gear, driven gear, and drive chain as an
• Using a suitable tool, pry between the two pry 15. Front output shaft from the front output bearing.
bosses to separate the case halves. 16. Oil pump assembly and mainshaft from the input
6. Clutch coil wire connector from the clutch coil wire carrier and front case half (figure 9).
(figure 4). 17. Shift rail, range fork, and shift hub from the input
7. Clutch coil nuts from the clutch coil assembly (fig carrier assembly (figure 10).
ure 4). 18. Annulus gear snap ring from the front case (figure
8. Clutch coil from the rear case half. 11 ).
9. Shift rail spring from the shift rail. 19. Annulus gear from the front case (figure 12).
10. Clutch coil housing snap ring and the clutch coil 20. Input shaft front oil seal from the front case.
housing from the mainshaft using snap ring pliers 21. Carrier assembly snap ring from the carrier assem
(figure 5). bly input shaft (figure 13).
11. Synchronizer hub from the synchronizer assembly. 22. Input carrier assembly and power take off drive
12. Synchronizer assembly from the mainshaft drive gear from the front case (figure 14).
gear and mode shift fork from the shift rail (figure 23. Retaining clip from the sector shaft (figure 15).
6 ). 24. Sector shaft from the front case.
Figure 11—Annulus Gear Snap Ring
25. Sector, detent spring, and detent roller from the

front case.
26. Front input bearing snap ring from the front case
(figure 16).
27. Front input bearing from the front case using
J 8092 and J 29169 (figure 17).
28. Rear output bearing from the rear case half using
J 8092 and J 33832.
29. Front output shaft rear bearing from the rear case
using J 2619-01 Slide Hammer and J 29369-1 Out
put Shaft Bearing Remover (figure 18).
30. Front output shaft seal from the front case.
31. Front output bearing snap ring from the front case
(figure 19).
32. Front output bearing from the front case using
n h s l / J 8092 and J 33832 (figure 20).
33. Rear output shaft seal from the rear bearing retain
er.
Figure 10—Shift Rail Range Fork and the Shift Hub
Figure 14— Input Carrier and PTO Gear Figure 17—Front Input Bearing Removal
SYNCHRONIZER HUB
ASSEMBLY
1. Synchronizer hub snap ring from the synchronizer

hub assembly.
2. Lockup hub and compression spring from the lock
up collar.
OIL PUMP ASSEMBLY

• Mainshaft from oil pump assembly.

1. Oil pump cover screws and oil pump cover from
the oil pump body.
2. Oil pump drive gear and driven gear from oil pump
body.
3. Retainer from the pick up tube.
J 33832
J 8092
Figure 20— Removing the Front Output Bearing

Removal
4. Pick up tube and oil pump pickup from the oil

pump body.
5. Oil pump pickup from the pick up tube.
6. Needle bearings from mainshaft.

15? Clean 6. All mating surfaces.
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.
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
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)
* Assemble (Figure 22) 1. Compression spring to the lockup collar.

2. Lockup hub compressing the compression spring.
1. Needle bearings to mainshaft. 3. Synchronizer hub snap ring.
2. Oil pump pickup to the pickup tube.
3. Pickup tube, oil pump pickup, and retainer to the oil INTERNAL COMPONENTS
pump body.
4. The oil pump drive gear and driven gear into oil
pump body.
• Lubricate the assembly with automatic transmis 23, and 24)
sion fluid.
5. Oil pump cover and oil pump cover screws to oil Tools Required:
pump body.
Tighten J 8092 Driver Handle
• Pump cover screws to 2.5 N.m (22 lbs. in.). J 29169 Bearing Installer/Remover
Inspect 1. Rear output shaft seal to the rear bearing retainer

using J 37668.
2. Front output bearing to the front case using J 8092
• Oil pump operation on the mainshaft. The main
shaft must turn freely within the oil pump. If and J 33832 (figure 23).
binding occurs, remove the cover, rotate the 3. Front output bearing snap ring to the front case
gears, and reinstall the cover. (figure 19).
4. Front output shaft seal to the front case using
J 37668.
5. Rear output bearing to the rear case using J 8092
and J 33832.
6. Front input bearing to the front case using J 8092
and J 29169 (figure 24).
7. Front input bearing snap ring to the front case (fig
ure 16).
8 Sector, detent spring, and detent roller to the front
case (figure 15).
9. Sector shaft through the case and align with spline
on the sector.
10. Retainer clip to the sector shaft.
11. Power take off drive gear and the input carrier
assembly to the front case (figure 14).
12. Input carrier snap ring to the input carrier (figure
13).
13. Input shaft front oil seal to the front case using J
37668.
14. Annulus gear to the front case (figure 12).
15. Annulus gear snap ring to the front case (figure
11).
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
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.
$ 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 • Bolt to 16 N.m (12 lbs. ft.).

$
5. Rear output yoke, rubber sealing washer, flat wash
Case screws to 41 N.m (30 lbs. ft.). er, and the rear output yoke nut to the rear output
shaft (figure 1).
Tighten Tighten
• Nut to 170 N.m (125 lbs. ft.). Nut to 224 N.m (165 lbs. ft.).
6. Front output yoke, rubber sealing washer, flat

washer, and the front output yoke nut to the front
output shaft.
SPECIFICATIONS
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 —
Capacity................................................................................................................................................................... 3.1L (3.3 qts.)
T2689
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
1. Bearing and Gear Puller

2. Puller
5. J 37668 4. Bearing Remover/Installer
5. Seal Installer
6. Driver Handle
7. Installer
8. Output Shaft Bearing Remover
9. Slide Hammer
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
10 1/2 inch Ring Gear.......................................... 4B4-2
(4.3L VIN Z )....................................................... 6A3B-28
11 inch Ring Gear................................................. 4B5-2
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
----------------------------------------------
Pi \d i ES

GMT 95 LUR 1995 GM Light Duty Truck Unit Repair Manual PDF

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GMT 95 LUR 1995 GM Light Duty Truck Unit Repair Manual PDF

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CAUTION

To reduce the chance of personal injury and/or property damage, the

The service procedures recommended and described in this service

Accordingly, anyone who intends to use a replacement part, service

It is important to note that this manual contains various ‘Cautions’ and

This vehicle is equipped with Supplemental Inflatable Restraint (SIR).

General Motors Corporation

SECTION SUBJECT CONTENTS

;jnieci e.b%>v to efoiriaV * .

'£ $ s d m u r j 9 {? 6 q b n * rirrifc > » 3 •

,«|fvoiq 73nnso Sedrfiun enoilq ssrtT •• i<v - v . . / 'i - :

lada-un enof* .. -U gnhi^eriG lerfncmeq ;i ■:~f ftd'flStiff

SPECIAL TOOL ORDERING • Model year and vehicle line

□ cm □ izzi tzzi □ □ izzi izzi izzi izzi tzzi c m

Figure 2—VIN Location

Figure 1—Service Parts Identification Label VEHICLE CERTIFICATION LABEL

VEHICLE IDENTIFICATION NUMBER (VIN)

Figure 3—Vehicle Identification Number

Figure 4—Vehicle Certification Label Figure 5—2.2L Engine I.D. Location

The payload rating shown on the label is the maxi­

1. Engine I.D. Location VIEW C

Figure 9—6.5L Diesel Engine I.D. Location

BUILD DAY OF MONTH

Figure 11—New Venture Gear 3500 Transmission I. D. Location

1. TRANSMISSION I.D. LOCATION

Figure 12—New Venture Gear 4500 Transmission i. D. Location

MODEL YEAR IjU L IA N tX T E I

HYDRA-MATIC 4L80-E/4L80-EHD TRANSMISSION IDENTIFICATION INFORMATION 3100r4921

Figure 14—Hydra-Matic 4L80-E Transmission I. D. Location

J1930 CONVERSION CHART

J1930 CONVERSION CHART

r^ o r " ib a ^ iq ffr ,0 t»fi‘ oillbu&O i!A c'ifC 0 2

1 — CLUTCH HUB KEY

6 — COIL & HOUSING

9 — O-RING, SHAFT SEAL

20 — WEEPAGE SEAL (FELT

COMPRESSOR - REAR HEAD

Fig. 1 Compressor Components — Disassembly

1 -J-33013-B HUB AND 2 -CLUTCH PLATE AND

Fig. 4 Clutch Plate & Hub Asm. Removal

COMPRESSOR CLUTCH PLATE AND HUB

1 -SUCTION PORT 1. If compressor is on the vehicle, loosen compressor

Thread the Clutch Plate and Hub Assembly Remover

Remove the shaft key. (Fig. 5.)

The shaft key is curved slightly to provide an

C. Plug clutch coil connector onto Clutch Coil.

Fig. 12 Bearing Removal

Fig. 14 Bearing Staking

Place the Pulley Rotor on the J 21352-A Support Block

1 - J 24092 PULLER LEGS

COMPRESSOR SHAFT SEAL

Seal Leak Detection

1 - J 25287 CLUTCH COIL PULLER Remove or Disconnect

2 - J 25031 GUIDE 1. Recover Refrigerant using J 39500-GM.

Fig. 19 Removing and Installing Seal and O-Ring

Insert the O-Ring Installer J 33011 completely down into

Fig. 22 High Pressure Cut-Off Switch and Retainer

Fig. 23 HR100T/HR110MD Compressor — Special Tools

When servicing the compressor, keep dirt or foreign

6 — SHAFT SEAL PARTS

11 — RETAINER RING SWITCH

13 — SPECIAL 134a SUCTION

Compressor — Rear Head

The payload rating shown on the label is the maxi