NEW PROCESS 231 TRANSFER CASE 7D3-3
4. Pump retainer housing (8) from the rear case half
(17).
5. Speedometer drive gear (11) from the m ainshaft
(19).
6. Case bolts (3) from the case halves.
• Note two longer case bolts and washers go
into doweled case holes (33).
• Separate case halves. Insert screwdrivers into the
slots cast in the case ends and pry apart. Do not
attempt to wedge the case halves apart at any point
on the mating surfaces.
• Be careful not to damage the oil pump (12)
(located in the rear case half) while removing
the rear case half (17).
INTERNAL COMPONENTS
+ +
Remove or Disconnect (Figures
3, 4,
and
5
through
9)
Tools Required:
J 8092 Driver Handle
J 36370 Bearing Installer/Remover
J 29170 Bearing Remover
J 29369-1 Bearing Remover
J 9276-21 Adapter
J 2619-01 Slide Hammer
J 33790 Bearing Remover
1. Oil pump (12) pickup tube (18), O-ring (14) and pump
pickup filter (35) from the rear case half (figure 5).
2. Fork shift spring (52).
3. Mainshaft (19), chain (58), and driven sprocket (22)
from the front case half (45) as as unit. Mode shift
fork (54) and shift rail (48) will be removed with the
mainshaft.
4. Retainer (snap ring) (83) from the mainshaft (19).
5. Synchronizer assembly (81). Drive sprocket (20)
from the m ainshaft (19) (figure 6).
6. Range shift fork (51) and range shift hub (34) and
sector with shaft (55) from the planetary carrier (36).
• It is necessary to rotate the sector with shaft
(55) to obtain clearance when removing the
range fork (51) (figure 7).
7. Shift lever nut (63), washer (64), shift lever (65),
plastic washer (66) and the O-ring seal (67) from the
front case half (45).
8. Input bearing retainer bolts (43) and input bearing
retainer (44) from the front case half (45).
9. Bearing retainer (snap ring) (39).
10. Planetary carrier (36) and the input gear (38) from
the annulus gear (62) using a soft faced hammer.
11. Input bearing (40) from the front case half (45) using
J 36370 and J 8092.
12. Drive sprocket bearings (82) from the drive sprocket
(20) using J 29170 and J 8092.
13. Needle bearings (84) from the input gear (38) using
J 29369-1, J 9276-21 and J 2619-01 (figure 8).
14. Front output shaft seal (72) from the front case half
(45).
15. Front output bearing retainer ring (snap ring) (60).
16. Front output bearing (61) from the front case half
(45) using J 33790 and J 8092.
17. Seal (1) from the mainshaft extension housing (4).
18. Seal (42) from the input bearing retainer (44).
19. Front output rear bearing (24) from the rear case
half (17) using J 2619-01 and J 29369-2 (figure 9).
20. M ainshaft bearing (6) from the oil pump retainer (8)
using J 33790.
21. Magnets (25) from the front case half (45).
D isassem ble
• Mark location of synchronizer hub and sleeve to aid
in assembly.
1. Main drive synchronizer stop ring (28) from the
synchronizer sleeve (29).
2. Spring retainer (32) from the synchronizer sleeve
(29).
3. Synchronizer hub (31) from the synchronizer (29).
4. Oil pump screws (79) from the oil pump (12).
5. Inner gear.
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...