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K TRUCK FRONT AXLE 4C4-11
39. Bearing Cup
/
F-5868
J 3 6 5 9 8 -3 (K 1 5 -2 5 )
PINION INSTALLATION
Figure 21 — Installing the Inner Pinion Bearing Cup
PINION DEPTH ADJUSTMENT
Tools Required:
J 36601 Pinion Depth Setting Gage
J 29763 Dial Indicator
1. Refer to figures 1 through 4 and 22.
2. Pinion depth is adjusted by selecting a shim (38) of
the proper thickness.
3. Lubricate the pinion bearings liberally with axle
lubricant.
4. A sse m b le J 29763 to th e p ro p e r g a g in g arm
(J 36601-4 for K15-25 models, J 36601-3 for K35
models).
5. Install the pinion bearings and hold them in place.
6
. Insert the threaded rod of J 36601 through the
pinion bearings.
7. Install the proper pilot, flat washer, and nut.
8
. Tighten the nut while holding the threaded rod with
a wrench to adjust bearing preload. Adjust the nut to
obtain a preload of 1.0-1
.6
N m (10-15 in. lbs.).
M easure using an inch pound torque w rench.
Rotate the shaft several times to make sure the
bearings have seated, then measure again.
9. Push the dial indicator downward until the needle
rotates about three turns.
10. Tighten the dial indicator in this position.
11. Set the button of J 36601 on the differential bearing
bore (figure
22
).
12. 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.
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 22). Record the dial indicator reading.
14. The dial indicator reading is equal to the required
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 “ Specifications.”
15. Remove the tool and bearing cones.
Install or C o nn ect (Figures 1 throu g h 4 and 11,
23 and 24)
Tools Required:
J 35512 Bearing Installer (K15-25 Models)
J 36614 Bearing Installer (K35 Models)
J 8614-01 Pinion Flange Remover
J 36333 Seal Installer
1. Shim (38) to the pinion gear (37).
• The shim must be of the proper size, as
selected previously.
2. Bearing (39) onto the pinion gear using J 35512
(K15-25 models) or J 36614 (K35 models) (figure 23).
3. New spacer (40) onto the pinion gear.
4. Bearing (41) into the case.
5. Seal (42) into the case using J 36366 (figure 24).
6
. Pinion gear, with bearing and spacer, to the case.
7. Deflector (43), flange (44), washer (45) and nut (46).
• Apply PST Sealant (GM part no. 1052080 or
equivalent) to the pinion gear threads and on
both sides of the washer.
• Tighten nut (46) until no end play is detectable
while holding the flange (44) with J 8614-01
(figure
11
).
• No further tightening should be attempted until
the bearing preload has been checked.
€
M easure (Figure 25)
Pinion bearing preload. Use an inch pound torque
wrench (figure 25). The correct preload is 1.7-2.8
N m (15-25 in. lbs.).
1. Rotate the pinion with the torque wrench and
observe the reading.
2. If the preload torque is below specifications,
co ntin ue to rq uin g the pinion nut in sm all
increm ents. C heck the preload after each
tig hte nin g. Each tig h te n in g 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 pinion several tim es to make sure that the
bearings have seated. Recheck the preload,
and adjust if necessary.
DIFFERENTIAL CASE ASSEMBLY
* n - Install or C onnect (Figures 1 throu g h 4, and
26)
Tools Required:
J 22761 S id e B e a rin g In s ta lle r (K 1 5-25
Models)
J 29710 Side Bearing Installer (K35 Models)
J 8092 Driver Handle
1. Side gear spacer (57) (K-35 m odels only), thrust
washers (53), and side gears (54) into the differential
case (35).
• Install the side gear spacer on the left-hand
shaft. K 15-25 models do not have a spacer.
• If the same gears and washers are being used,
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...