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7B2-8 HM-117 TRANSMISSION
B-05178
Figure 13 -R e m o vin g the Mainshaft from the 1st
and 2nd Speed Synchronizer Hub
• Support the hub on J 8176 and press the
mainshaft out, (figure 13).
Im portant
• Do not let the mainshaft fall to the floor.
7. 2nd speed gear bushing (244).
• Use a cold chisel to split the bushing if it is
worn or damaged.
Im portant
• Do not scratch or gouge the mainshaft.
8
. 3-4 synchronizer (205), (figure 14).
• The synchronizer hub and sleeve are a select
fit. Do not mix the parts of the two
synchronizers.
1JJI
5.
6
.
8
.
9.
10
.
• Mark the hub and sleeve alignment for
reassembly.
• Push the hub out of the sleeve while holding
the springs and keys to avoid loosing them.
Clean
All parts in a suitable solvent and air dry.
Im p o rtan t
• Do not spin dry the bearings.
Inspect
Gears for cracks, chipped gear teeth, and other
damage that could cause gear noise.
Thrust washers and bushings for damage and wear.
Related surfaces on the gears like thrust faces and
bearing surface diameters.
The reverse sliding gear for a sliding fit on the
synchronizer hub without excess radial or circular
play. If the sliding gear is not free on the hub,
inspect it for burrs on the ends of the internal
splines. Remove any burrs by honing as required.
Synchronizer sleeves for a sliding fit on the
synchronizer hubs and for the hubs a snug fit on the
mainshaft splines.
Synchronizer springs and keys for looseness and
damage.
Brass synchronizer rings for excess wear and
damage.
All gear teeth for excess wear.
Bearings and bearing surfaces for nicks, burrs and
wear.
Lubricate all roller bearings with light engine oil and
check for rough rotation.
*
A ssem ble (Figure 11)
Tools Required:
J 22873 Mainshaft Bushing Installer
J 22875 3rd Gear Assembly Tool
N O TIC E: The m a in s h a ft 1st, 2 n d a n d 3 rd s p e e d
g e a r b ush ing s are s in te re d iron . The bushings
M U S T BE PRESSED ON SEPARATELY (N O T WITH
THE H UBS) OR THE BUSHING S WILL BE SMASHED
CAUSING A PREMATURE FAILURE (O R LO C K UP)
BECAUSE OF NO ENDPLAY FOR THE SPEED GEARS.
1
.
3-4 synchronizer (205), (figure 15).
• Place the keys in the hub.
• Engage the springs in different slots in either
side of the hub so they support all the keys.
• Slide the sleeve onto the hub aligning the
marks made during disassembly.
2nd speed bushing, using J 22873, (figure 16).
1-2 synchronizer hub (210), (figure 17).
• A minimum press of 681 kg (1500 lbs.) is
required to move the hub.
• The annulus must be to the rear of the shaft.
Synchronizer keys and the springs.
1st speed bushing (245), using J 22873, (figure 18).
2nd speed blocker ring, the 2nd speed gear (209)
and the 3rd speed thrust washer (243) (figure 19).
• The tab on the thrust washer must be in the
slot in the mainshaft.
Figure 1 4 —S y n c h ro n ize r C om po n ents
7. 3rd speed bushing (242) using J 22875 (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...