1989
UNIT REPAIR
MANUAL
COVERING
LIGHT DUTY
TRUCKS
The T able of C on te nts on th is page indi
cates the se ction s co vered in th is m anual.
At the b e g in nin g of each ind ivid ua l section
is a T ab le o f C o n te n ts w h ic h g iv e s the
page n um be r on w hich each m ajor su b je ct
begins.
W hen reference is m ade in th is m anual
to a brand nam e, num be r, or sp e c ific tool,
an e q u iv a le n t p ro d u c t m a y be used in
place of the re co m m en d ed item .
All inform a tion , illu stra tio n s, and s p e c ifi
c a tio n s c o n ta in e d in th is M a n u a l a re
based on the latest p ro d u c t inform a tion
a v a ila b le at th e tim e of p u b lic a tio n a p
p ro v a l. T h e rig h t is re s e rv e d to m a k e
ch an ge s at any tim e w ith o u t notice.
X -8937
© 1988 G eneral M otors C orpo ratio n June, 1988
P rinted in USA.
All rights reserved.
TABLE OF CONTENTS
SEC.
SECTION NAME
OA
GENERAL INFORMATION
1
AIR CONDITIONING
1B1
A6 Air Conditioning Compressor
1B2 V 5 Air Conditioning Com pressor
1B3 R-4 Air Conditioning Com pressor
1B4 H R -6 Air Conditioning Com pressor
1 B5 S D -7 09 Air Conditioning Com pressor
3
STEERING
3B 2 M anual Steering G ear
3B 3 Power Steering
4
AXLES
4B
R ear Axle
4B1
7 1/2 Inch Ring G ea r
4B 2 8 1/2 Inch Ring G ea r
4B 3 9 1/2 Inch Ring G ear
4B 4 10 1/2 Inch Ring G ear
4B 5 Dana R ear Axles
4B 6 12 Inch Ring G ea r (Rockwell)
4B 7 Locking Differentials
4C
Front Axle
4C1
8 1/2 Inch Ring G ear
4 C 2 9 3/4 Inch Ring G ear
4 C 3 T Truck Front Axle
4 C 4 K Truck Front Axle 8 1 /4 and 9 1 /4 Inch
Ring G ear
5
BRAKES
6
ENGINE
6A
G eneral Engine
6A1
2.5 Liter L4
6A 2 2.8 Liter V 6
6A 3 4 .3 Liter V 6
6A 4 4.8 Liter L6
6A 5 V 8 Engine
6A 7 6 .2 Liter Diesel
6C
Carburetor and TBI Unit
6C1
Model 1 M E F Carburetor
6C 2 Model M 4 M E F Carburetor
6C 3 TBI Unit Model 220
6C 4 TBI Unit Model 700
6D
Engine Electrical
6D1
SI Series G enerators
6D 2 C S -144 G enerator
6D 3 S D (M T) Starting Motors
6D 4 P G -200 (P M G R ) Starting Motor
6D 5 Distributors
7
TRANSMISSION
7A
Automatic Transmission
7A1
700-R 4 Automatic Transm ission
7A2 4 0 0 /4 7 5 Automatic Transm ission
7A3 180C Automatic Transm ission
7B
M anual Transmission
7B1
H M -2 90 M anual Transm ission
7B 2 H M -1 17 Transmission
7B 3 New Process Transm ission
7B 4 Borg-W arner Transmission
7D
Transfer C ase
7D1
New Process 20 5 Transfer C ase
7D 2 New Process 241 Transfer Case
7D 3 New Process 231 Transfer C ase
7D 4 Borg W arn er 1370 Transfer C ase
f
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...