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• The housing for cracks. Replace the housing if any
cracks are found.
• The housing for foreign material such as metal
chips, dirt, or rust. Refer to “ Cleaning."
DIFFERENTIAL
Inspect
• Pinion gear shaft for unusual wear.
• Pinion gear and side gear teeth for wear, cracks,
scoring, and spalling.
• Thrust washers for wear.
• The fit of the side gears in the differential case.
• The fit of the side gears on the axle shafts.
• Differential case for cracks and scoring.
• All parts for wear and replace if necessary.
PINION AND RING GEAR
Ring and pinion gears are matched sets and both are
replaced any time a replacement of either is necessary.
SHIMS
l ?
Inspect
• Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.
• Pinion gear splines for wear.
• Pinion flange splines for wear.
• The fit of the pinion gear splines on the pinion
flange.
• The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks that could cause dam
age to the seal’s inside diameter and result in an
oil leak.
• All worn or broken parts and replace if necessary.
Important
A new pinion flange must also be replaced when
ring gear and pinion gear are replaced to maintain
proper system balance.
BEARINGS
Inspect
Bearings for smooth rotation after oiling them.
Bearing rollers for wear.
Bearing cups for wear, cracks, brinelling, and scor
ing.
Important
When replacing worn or cracked bearings and
cups, make sure to to replace them in sets.
Ring gear and pinion gear for wear and replace
them as a set if worn.
Important
• Low m ile a g e b e a rin g s m ay have very sm all
scratches and pits on the rollers and the bearing
cups from the initial preload. Do not replace a
bearing for this reason.
I ?
Inspect
• Shims for cracks and chips. Damaged shim s
should be replaced with an equal size service
shim.
ASSEMBLY OF TH E REAR AXLE
-►+ Install or Connect (Figures 2 and 12 through
28)
Tools Required:
J 29710 Differential Side Bearing Installer
J 7818 Rear Pinion Bearing Cup Installer
J 8092 Driver Handle
•P inion bearing cups using J 29710, J 7818, and
J 8092.
PINION DEPTH ADJUSTMENT
Tools Required:
J 21777-40 Rear Pilot Washer
J 21777-42 Front Pilot Washer
J 21777-43 Stud Assembly— Bolt
J 21777-45 Side Bearing Discs
J 23597-1 Arbor
J 23597-11 Gage Plate
J 8001 Dial Indicator
1. Clean all the gage parts.
2. Lubricate the front and rear pinion bearings with
axle lubricant (figures 14 and 15).
3. Place the bearings into the pinion bearing cups.
Summary of Contents for S Series 1994
Page 1: ......
Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location...
Page 24: ...NOTES...
Page 26: ......
Page 69: ...NOTES...
Page 71: ...3 2 STEERING...
Page 73: ......
Page 84: ......
Page 102: ...40...
Page 130: ...NOTES...
Page 146: ...NOTES...
Page 162: ...NOTES...
Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage...
Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential...
Page 190: ...NOTES...
Page 202: ...NOTES...
Page 206: ...F5785...
Page 212: ...B Button Moved Out of Bearing Bore F5791...
Page 228: ...NOTES...
Page 232: ......
Page 234: ......
Page 236: ...Adjuster 63 Bolt 64 Lock Figure 10 Turning the Adjuster Plug K3 Models...
Page 237: ...Figure 13 Removing the Pinion Seal 39 Bearing Cup Figure 16 Removing the Inner Bearing Cap...
Page 261: ...F7475...
Page 267: ...B Button Moved Out of Bearing Bore F5791...
Page 294: ...NOTES...
Page 300: ...NOTES...
Page 318: ...NOTES...
Page 322: ...SR207LN2 EDS...
Page 324: ......
Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS...
Page 368: ...103 153 127 V1200...
Page 370: ......
Page 372: ......
Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft...
Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft...
Page 399: ...V2974...
Page 410: ......
Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924...
Page 452: ......
Page 454: ...163 164 V1202...
Page 456: ...20 21x 302 210 4 0 41 2 5 2 5 1 2 51 4 2 e3 54 3 9 252 252 S 255 255 25 6 256 209 V1196...
Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204...
Page 460: ......
Page 510: ......
Page 512: ...V2131...
Page 514: ...110 106 106 103 90 93 89 88 87 86 v 7 7 7 7 j A _ 111 f t 2 a a s 53 49 L 47 46 3706r4751...
Page 516: ...259 260 150 237 S lM 180 167180 J 1 82 183 170 169 1 1 78 1 7 9 213212 2 0 7 205 r i 3706r4752...
Page 566: ...NOTES...
Page 574: ...NOTES...
Page 618: ...SPECIAL TOOLS...
Page 620: ...NOTES...
Page 672: ......
Page 682: ......
Page 686: ......
Page 694: ...RH0213 4L60 E...
Page 695: ...657 659 m i J 8092 H J 34196 4 3 34196 5 657 658 665 J 23907 J 7004 1 J 8092 RH0214 4L60 E...
Page 696: ...J 8092 J 34196 4 33 31 J 8092 RH0215 4L60 E...
Page 697: ...SPECIAL TOOLS...
Page 698: ...SPECIAL TOOLS...
Page 758: ...RH0194 4L80 E...
Page 764: ......
Page 770: ...SPECIAL TOOLS...
Page 771: ...SPECIAL TOOLS CONT...
Page 772: ......
Page 775: ......
Page 776: ......
Page 785: ......
Page 804: ...NOTES...
Page 806: ......
Page 808: ......
Page 822: ...3707r5079...
Page 840: ......
Page 848: ...NOTES...
Page 852: ......
Page 860: ...F5435...
Page 866: ......
Page 878: ...F9167...
Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836...
Page 890: ...F9168...
Page 908: ......
Page 919: ......