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4B1-6 71/z AND 7
5
/s-INCH RING GEAR AXLES
T ig h ten
DIFFERENTIAL CASE ASSEMBLY
• Stud nut to 2.2 N m (20 in. lbs.).
6
. R otate th e g ag e p la te and b e a rin g s se veral
complete revolutions to seat the bearings.
7. Tighten the stud nut until a torque of 1.6 to 2.2 N m
(15 to 25 in. lbs.) is obtained to keep the gage plate
in rotation.
8
. Assembly J 21777-45, J 23597-11, and J 8001 to the
differential bearing bores as shown in figure 9.
• The bearing bores must be clean and burr
free.
9. Install the side bearing caps and tighten the bolts
finger tight.
10. Rotate the gage plate until the gaging areas are
parallel with the disks.
11. Position the gage shaft assembly in the carrier so
that the dial indicator rod is centered on the gage
area of the gage block.
12. Set the dial indicator at zero. Push the indicator
down on the indicator shaft until the needle rotates
approximately 3U of a turn to the right. Tighten the
dial indicator in this postion.
13. Rotate the gage shaft slowly back and forth until the
dial indicator reads the greatest deflection (when the
indicator needle is centered between moving to the
left and to the right).
14. At the point of greatest deflection, set the dial
indicator to zero. Repeat the rocking action of the
gage shaft to verify the zero setting.
15. Rotate the gage shaft until the dial indicator rod
does not touch the gage block.
16. Record the actual num ber on the dial indicator and
not the number which represents how far the needle
travels. This is the nominal pinion setting.
EXAMPLE: If the indicator needle moved to the left
1.70 mm (0.067-inch) to a dial reading of 0.84 mm
(0.033-inch) as shown in figure 10, 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 the 1.27
mm (0.020 to 0.050-inch) range.
17. Check the pinion face for a pinion adjustment mark.
This mark indicates the best running position for the
pinion from the nominal setting.
• If the pinion is stamped with a plus number,
add that many thousandths to the nominal
setting. If the nominal setting is 0.033-inch and
the pinion is marked +
2
, the correct shim
depth would be 0.033-inch + 0.002-inch =
0.035-inch.
• If the pinion is stamped with a minus number,
subtract th at m any th ou san d ths from the
nom inal setting. If the nom inal setting is
0.033-inch and the pinion is marked -2, the
correct shim depth would be 0.033-inch -
0.002-inch = 0.031-inch.
• If the pinion has no plus or minus marked on
the pinion, use the nominal pinion setting to
select a shim.
18. Remove bearing caps (31) and depth gaging tools.
19. Install the correct pinion shim (19) according to this
procedure to the pinion.
■H- Install or C o nnect (Figure 1)
Tools Required:
J 25299 Differential Side Bearing Installer
J 8092 Driver Handle
J 8107-2 Differential Side Bearing Remover
Plug
• Lubricate all parts with rear axle lubricant.
1
. Side gear thrust washers (28) to the side gears (26).
2
. Side gears (28) to the differential case (24).
• Place the side gears in place on the same side
as removed.
3. Pinion gears (28) to the differential without the thrust
washers (27).
• Place one pinion gear onto the side gears and
rotate the gears until the pinion is exactly
opposite from the differential opening.
• Place the second pinion gear onto the side
gears so that the pinion gear holes line up.
• Rotate the pinion gears into place, and veryify
that the pinion gears line up with the pinion
shaft holes.
4. Pinion thrust washers (27).
• Rotate the pinion gears toward the differential
opening just enough to slide in the pinion
thrust washers.
5. Pinion shaft.
6
. Pinion shaft screw.
• Check that the mating surfaces of the differential
case and the ring gear are clean and burr free.
7. Ring gear (20) to the differential case (24) (figure
11
).
• Thread two left-hand threaded studs into the
ring gear on opposite sides.
• Place the ring gear onto the case, and align
the studs with the holes in the case.
8
. New ring gear bolts (25).
• T ighten the ring gear bolts a lternately in
stages gradually pulling the ring gear onto the
differential case.
$
Tig h ten
• The ring gear bolts in sequence to 120 N m
(90 ft. lbs.).
9. D iffe re n tia l side b e a rin g s (22) using J 25299,
J 8092, and J 8107-2 (figure 12).
• Place J 8107-2 into the differential on the side
opposite of bearing installation to protect the
differential case.
• Drive the bearing onto the case using J 25299
and J 8092.
10. Differential case (24) to the axle housing. Refer to
“ Side Bearing Pre-Load A djustm ent” in this section.
SIDE BEARING PRE-LOAD ADJUSTMENT
• The side bearing pre-load adjustm ent must be
made before installing the pinion.
• The case side bearing pre-load is adjusted by
changing the thickness of both the left and right
shim s equally. T his w ill m aintain the o rig in a l
backlash.
Summary of Contents for 1989 Light Duty Truck
Page 1: ...vr V Light Duty Truck Unit Repair Manual...
Page 2: ......
Page 11: ...GENERAL INFORMATION OA 5 Figure 8 RV Models...
Page 13: ...GENERAL INFORMATION OA 7 Figure 11 ST Models...
Page 18: ......
Page 44: ......
Page 76: ...1B3 18 R 4 AIR CONDITIONING COMPRESSOR N...
Page 114: ......
Page 162: ......
Page 176: ...4B3 14 91 2 INCH RING GEAR...
Page 192: ...4B5 4 DANA REAR AXLES Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...
Page 218: ......
Page 220: ...4B6 2 12 INCH RING GEAR ROCKWELL F 04734 Figure 1 Rear Axle Components...
Page 229: ...12 INCH RING GEAR ROCKWELL 4B6 11 SPECIAL TOOLS Special Tools...
Page 230: ...4B6 12 12 INCH RING...
Page 240: ...4B7 10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Page 260: ...4C2 6 93 4 INCH RING GEAR FRONT AXLE Figure 16 Removing the Pinion Inner Bearing...
Page 273: ...T TRUCK FRONT AXLE 4C3 3 F 05785 Figure 1 Axle Components...
Page 291: ...K TRUCK FRONT AXLE 4C4 3 Figure 1 Front Axle Com ponents K 15 25 Models...
Page 293: ...K TRUCK FRONT AXLE 4C4 5 Figure 3 Front Axle Com ponents K35 Models...
Page 318: ...C4 30 K TRUCK FBOHT AXLE...
Page 334: ......
Page 361: ...2 5 LITER L4 ENGINE 6A1 5 Figure 3 Cylinder Head Manifolds and Components...
Page 363: ...2 5 LITER L4 ENGINE 6A1 7 F 05715 Figure 5 Block and Components...
Page 395: ...2 8 LITER V 6 6A2 3 Figure 1 Engine Lubrication Diagram...
Page 396: ...6A2 4 2 8 LITER V 6 Figure 2 Engine Lubrication Diagram...
Page 424: ...6A2 32 2 8 LITER V 6...
Page 427: ...I 4 3 LITER V 6 6A3 3 Figure 1 Engine Lubrication Diagram B 07857...
Page 451: ...4 3 LITER V 6 6A3 27 SPECIFICATIONS ENGINE SPECIFICATIONS F 6344...
Page 457: ...4 8 LITER L6 6A4 3 Figure 2 Lubrication Diagram Front View...
Page 460: ...6A4 6 4 8 LITER L6 C 1 107 112 fK 108 3 109 165 129 B 05056 Figure 5 Block and Components...
Page 490: ...Ml...
Page 493: ...V8 ENGINE 6A5 3 Figure 1 Lubrication Diagram 5 0L and 5 7L Engines...
Page 494: ...6A5 4 V8 ENGINE Figure 2 Lubrication Diagram 5 0L and 5 7L Engines...
Page 530: ...6A5 40 V8 ENGINE Figure 81 Exhaust Manifold 7 4L Engines Figure 82 Water Pumps and Components...
Page 571: ...6 2 LITER DIESEL 6A7 35 Figure 58 Vacuum Pump Installed...
Page 576: ......
Page 582: ...6C1 6 MODEL 1MEF CARBURETOR Figure 9 Monojet Model 1MEF...
Page 604: ...6C2 6 MODEL M4MEF CARBURETOR Figure 9 Model M4MEF...
Page 640: ...6C4 8 MODEL 700 THROTTLE BODY...
Page 652: ...nmm...
Page 672: ......
Page 693: ...DISTRIBUTORS 6D5 13 Figure 27 Testing the Pickup Coil Figure 28 Testing the Ignition Coil...
Page 696: ......
Page 698: ...7A1 2 700 R4 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts J H 0 0 5 3 7 0 0 R 4 R 2...
Page 745: ...700 R4 AUTOMATIC TRANSMISSION 7A1 49...
Page 762: ...7A2 2 400 475 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts H H 0021 400 R 3...
Page 773: ...400 475 AUTOMATIC TRANSMISSION 7A2 13 Figure 29 Internal Parts H H 0 0 4 3 4 0 0 R 2...
Page 797: ...400 475 AUTOMATIC TRANSMISSION 7A2 37 Figure 93 Control Valve Assem bly...
Page 803: ...400 475 AUTOMATIC TRANSMISSION 7A2 43 Figure 104 Bushing Replacement Procedure...
Page 808: ...J c I i sal...
Page 838: ......
Page 840: ......
Page 842: ......
Page 850: ...7B1 12 HM 290 MANUAL TRANSMISSION J i t i a x V L...
Page 856: ...7B1 18 HM 290 MANUAL TRANSMISSION...
Page 892: ...7B1 54 HM 290 MANUAL TRANSMISSION Figure 93 Special Tools...
Page 897: ...HM 117 TRANSMISSION 7B2 5...
Page 901: ...HM 117 TRANSMISSION 7B2 9 B 05180 Figure 17 Installing the 1st and 2nd Synchronizer...
Page 912: ...20 HM...
Page 924: ...7B3 12 NEW PROCESS TRANSMISSION SPECIAL TOOLS...
Page 927: ...BORG WARNER TRANSMISSIONS 7B4 3 Figure 2 77 mm Transmission and Components...
Page 940: ...i ii iii m i in m i...
Page 944: ...7D1 4 TRANSFER CASE FO 5688 Figure 3 NP205 Transfer Case...
Page 952: ...7D1 12 TRANSFER CASE...
Page 963: ...NEW PROCESS 241 TRANSFER CASE 7D2 11 Figure 17 Oil Pump Pickup Screen Doweled Case Holes...
Page 964: ...7D2 12 NEW PROCESS 241 TRANSFER CASE Figure 18 NP 241 Transfer Case Cut Away...
Page 978: ......
Page 981: ...BORG WARNER 1370 TRANSFER CASE 7D4 3 J...
Page 992: ...7D4 14 BORG WARNER 1370 TRANSFER CASE Figure 26 Installing the Rear Output Yoke...
Page 993: ...BORG WARNER 1370 TRANSFER CASE 7D4 15 Figure 27 BW 1370 Transfer Case...
Page 997: ......
Page 998: ...X 8937...