NEW PROCESS 231 TRANSFER CASE 7D3-5
1. O il Seal
2. B u s h in g
3. Rear E x te n s io n H o u s in g
B o lts /C a s e B o lts
4. Rear E x te n s io n
5. R e ta in e r S nap R ing
6. F ro n t O u tp u t B e a rin g
7. P um p R e ta in e r H o u s in g
B o lts
8. P um p R e ta in e r H o u s in g
11. S p e e d o m e te r D rive G e ar
12. O il P um p
13. O il P um p Seal
14. O -R ing
15. Plug
16. B o lt
17. Rear C ase H a lf
18. O il P um p P ick Up Tube
19. M a in s h a ft
20. Drive S p ro c k e t
21. F ro n t O u tp u t S h a ft
24. F ro n t O u tp u t Rear B e aring
25. M ag ne t
26. O il Tube C o n n e c to r
27. W a sh er
28. M ain Drive S y n c h ro n iz e r
S to p R ing
29. S y n c h ro n iz e r Sleeve
30. S tru t
31. S y n c h ro n iz e r H ub
32. S p rin g R e ta in e r
33.
D ow el
34.
R ange S h ift H u b
35.
P u m p P ic k Up S creen
36.
P la n e ta ry C a rrie r
37. T h ru s t W a sh e r
38. In p u t G ear
39.
R e ta in e r S nap R ing
40. In p u t B e aring
42.
In p u t B e a rin g R e ta in e r
Seal
43.
In p u t R e ta in e r B o lt
44. In p u t B e a rin g R e ta in e r
45.
F ro n t C ase H a lf
46. In d ic a to r Lam p S w itc h
47. O -R ing Seal
48. S h ift Rail
49.
Pads
50. Pads (C enter)
51. R ange S h ift Fork
52.
F ork S h ift S p rin g
53.
Pin
54.
M od e S h ift Fork
55. S e c to r W ith S h a ft
56.
B u s h in g
57.
R ange F ork Pin
58. C ha in
59. R e ta in e r S nap R ing
60. R e ta in e r S nap R ing
61. F ro n t O u tp u t B e aring
62. A n n u lu s G ear
63. S h ift Lever N ut,
Prev. Torque
64. W a sh er
65. S h ift Lever
66. W a s h e r P la s tic
67. O -R ing Seal
68. P o pp e t S crew
69. O -R ing Seal
70. S e le c tio n P lu n g e r
71. P o pp e t S p rin g
72. F ro n t O u tp u t S h a ft Seal
73. D e fle c to r
74. F ro n t O u tp u t Yoke
75. R u b b e r S e a lin g W a sh e r
76. W a s h e r
77. N u t F ro n t O u tp u t Yoke
78. C a rrie r L ock R ing
79. O il P u m p S crew
80. Id e n tific a tio n Tag
81. S y n c h ro n iz e r A s s e m b ly
82. D rive S p ro c k e t B e a rin g
83. M o d e S y n c h ro n iz e r H ub
S nap R ing
84. M a in s h a ft P ilo t B e a rin g
F-05850
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A
Figure 4—New Process 231 Transfer Case
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...