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• Differential case for cracks and scoring.
• Thrust sleeve for excessive wear. Do not replace
the thrust sleeve unless necessary. Inspect the
side gear bore for scoring. If scoring is present,
replace the entire differential.
• All parts and replace if necessary.
CAM UNIT ASSEMBLY - 7 1/2, 7 5/8, AND 8
1/2-INCH
Install or Connect (Figures 1 and 3)
1. Cam plate (16) to the side cam gear (21).
2. Wave washer (15).
3. Clutch plates (12) (7 1/2 and 7 5/8 = 8 plates. 8 1/2
= 10 plates).
• Alternate the plates as shown in figure 1.
4. Retaining ring (22) (figure 3).
5. Guide clips (20) to the clutch plates (12).
• Use grease in the clips to hold them in place on
the plates.
CAM UNIT ASSEMBLY - 9 1/2-INCH
-►+
Install or Connect
1. Cam plate (16) to the side cam gear (21).
2. Wave washer (15).
3. Clutch plates (12).
• Alternate the plates as shown in figure 1.
4. Thrust sleeve (14).
• Press the thrust sleeve flush with the side gear
disc splines.
5. Guide clips (20) to the clutch plates (12).
• Use grease in the clips to hold them in place on
the plates.
A. If the side cam gear or side thrust sleeve has
been replaced, measure and record the overall
length of the gear assembly from the front of
the gear to the back of the side thrust sleeve
(14) including the side gear thrust washer (13).
B. Compare this reading with the reading obtained
earlier in this section.
C. If the new reading is more than 0.0762 mm
(0.003 inch) higher or lower than the original,
select a thrust washer that will return the read
ing closest to the original reading.
ADJUSTMENT OF THE DIFFERENTIAL
• If it is necessary to replace the cam gear, right side
gear, or thrust block, the entire differential must be
adjusted. The differential is adjusted by using
selective thickness thrust washers behind each
side gear and selective thickness reaction blocks.
• It is important to build up the differential properly.
The proper clearance between parts is critical to
the operation of the unit.
• There are three adjustments needed:
(1) Left side gear backlash.
(2) Right side gear backlash.
(3) Thrust block clearance.
Left Side Gear Backlash Adjustment
1. Install the cam unit and side thrust washer (13) to
the flange end of the case.
2. Place the pinion gears (7) and side gear thrust
washers into the differential.
• Align them with the pinion shaft hole.
3. Press down the side gear, and install the pinion
shaft (18) and lock screw (3).
• If the side gear cannot be pressed down far
enough to install the pinion shaft, replace the
side gear thrust washer with a thinner washer.
4. Rotate the pinion gear closest to the lock screw so
one of the teeth is pointing downward (perpendicu
lar to the ring gear flange).
5. Insert a large tapered tool, like a screwdriver, firmly
between the side gear and the pinion shaft.
6. Mount a dial indicator to the ring gear flange and
place the stem of the indicator on one of the teeth on
the pinion gear closest to the lock screw (figure 5).
7. Pull the pinion gear firmly into its seat, and rotate
the gear back and forth while reading the dial indi
cator. Record the reading.
8. Repeat steps 4 through 7 on the opposite pinion
gear.
9. The backlash should be between 0.254 and
0.457 mm (0.010 and 0.018 inch).
10. If the backlash is too high, use a thicker side gear
thrust washer.
11. If the backlash is too low, use a thinner side gear
thrust washer.
Right Side Gear Backlash Adjustment
1. Assemble the clutch plates.
• Alternate the plates as shown in figure 1.
2. Assemble the guide clips (19) to the plates.
• Use grease in the clips to hold them in place on
the plates.
3. Install the side gear thrust washer (8), clutch plate
assembly (9), and right side gear to the differential.
4. Place the pinion gears (7) and thrust washers (6)
into the differential.
• Align them with the pinion shaft hole.
5. Press down on the side gear, and install the pinion
shaft (18) and lock screw (3).
• If the side gear cannot be pressed down far
enough to install the pinion shaft, use a thinner
side gear thrust washer.
6. Rotate the pinion gear closest to the lock screw so
that one of the teeth is pointing downward (perpen
dicular to the ring gear flange).
7. Insert a large tapered tool, like a screwdriver, firmly
between the side gear and the pinion shaft.
8. Mount a dial indicator to the ring gear flange, and
place the stem of the indicator on one of the teeth on
the pinion gear closest to the lock screw (figure 5).
9. Pull the pinion gear firmly into its seat, and rotate
the gear back and forth while reading the dial indi
cator. Record the reading.
10. Repeat steps 6 through 9 on the opposite pinion
gear.
11. The backlash should be between 0.051 and 0.243
mm (0.002 - 0.010 inch).
12. If the backlash is too high, use a thicker side gear
thrust washer.
13. If the backlash is too low, use a thinner side gear
thrust washer.
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: ......