4C4-4 K TRUCK FRONT AXLE
1.
Shaft
32. Sleeve
2.
D eflector
33. Side B earing
3.
Seal
34. Bolt
4.
Bearing
35. D ifferential Case
5.
Tube
36. Pin
6.
Bolt
37. Ring and Pinion
7.
T hru st W a sh er
G ears
8.
R etaining R ing
38. Shim
9.
C arrie r C on ne cto r
39. Bearing
10. Solenoid
40. S pacer
13. Indicator Sw itch
41. Bearing
14. Spring
42. Seal
15. Clip
43. D eflector
16. S hift Fork
44. Flange
17. D am per S pring
45. W asher
18. S hift Shaft
46. Nut
20. Shim
48. Bushing
21. D ifferential Pilot
51. Lock
B earing
52. Shaft
22. Sleeve
53. T hru st W asher
23. O u tp ut Shaft
54. Side G ear
25. Plug
55. T hru st W asher
26. W asher
56. D ifferential Pinion
27. Pin
G ear
28. Bolt
58. Bolt
29. C arrier Case
59. Shaft
30. B earing
60. V ent Plug
31. Insert
F-6498
Figure 2— Front Axle Components (K15-25 Models)
22. Sleeve(s) (32) and side bearing (33) cups (right side
only on K35).
• Turn the sleeve(s) to push the bearing cup(s)
out of the bore(s). Use J 36599 (figure 9).
23. Adjuster plug (61) with side bearing cup (33) and CD-
ring (62) (K35 models). Use J 36615 (figure 10).
24. Nut (46). Use J 8614-01 to hold the pinion flange (fig
ure 11).
25. Flat W asher (45).
26. Flange (44) with deflector (43). Use J 8614-01 (figure
12
).
• Mount the left carrier case in J 36598. Be sure to use
the adapter plate (J 36598-6) for K15-25 models.
27. Pinion (37) with shim (38), bearing cone (39), and
spacer (40). Use J 36598 (figure 13).
28. Spacer (40) from the pinion.
29. Pinion bearing (39). Use J 8612-B (K15-25 models) or
J 36606 (K35 models) and a press (figure 14).
30. Shim (38).
31. Seal (42), and bearing cup and cone (41). Use
J 36598 (figure 15).
32. Bearing cup (39). Use J 36598 (figure 16).
33. Side bearings (33). Use J 22888-D and J 8107-2 (K15-
25 models) or J 36597 (K35 models) (figure 17).
34. Ring gear bolts (34).
• Ring gear bolts have left-handed threads.
NOTICE: Do n o t pry the ring g e a r from th e case.
This will d a m a g e the ring g e a r a n d the differe ntial
case.
35. Ring gear (37) from the differential case.
• Drive the ring gear off with a brass drift.
36. Roll pin (36) (K15-25 models). Drive out with a drift
and hammer (figure 18).
37. Bolt (24) (K35 models).
38. Shaft (52).
39. Differential pinion gears (56) and side gears (54).
• Roll the pinion gears out of the case with the
pinion thrust w ashers (55).
• Remove the side gears and the side gear thrust
washers (53). Mark the gears and the differen
tial case as left and right.
• Remove spacer (57) (K35 models only).
40. Vent plug (60). Use a 6-point deep socket.
41. Bushings (48). Use J 36616 (figure 19).
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...