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DISASSEMBLY
Disassemble (Figure 1 through 15)
Tools Required:
J 2619-01 Slide Hammer
J 29369-2 Seal Remover
J 8614-01 Pinion Flange Remover
J 21551 Bearing Remover
J 22912-01 Pinion Bearing Cone Remover
J 29307 Slide Hammer
J 33791 Bushing Remover
J 33792 Side Bearing Adjuster Wrench
J 33837 Pinion Bearing Cup Remover Kit
J 34011 Output Shaft Pilot Bearing Remover
1. Bolts (6), shift cable housing (11), and spring (14).
2. Tube (5), and thrust washer (7).
3. Spring (16), and shift shaft with fork (17).
4. Axle shaft (1) with deflector (2).
A. Clamp the axle tube (5) in a vise. Clamp ONLY
on the mounting flange.
B. Strike the inside of the shaft flange with a brass
hammer to dislodge the shaft.
5. Carrier connector (9) with retaining ring (8).
6. Right seal (3) and bearing (4), using J 29369-2 and
J 29307 (figure 3).
7. Seal (15) from the tube (5). Pry out with a screw
driver.
8. Thrust washer (20).
9. Sleeve (22) and output shaft (23).
10. Differential pilot bearing (21) from the output shaft,
using J 34011 (figure 4).
11. Washer (24).
12. Shaft (59), and deflector (2).
• Using J 2619-01, pull the output shaft out of the
case (figure 5).
13. Bolts (58) and cover (57).
14. Left seal (3).
15. Bolts (28).
16. Separate the carrier case (29).
• Insert a screwdriver into the slots provided and
pry to separate the case (figure 6).
17. Differential case (35).
18. Bolts (18) and lock tabs (19) from the side bearing
adjuster sleeves (32) (figure 7).
19. Bearing cups (33) and sleeves (32) from the case.
• Turn the sleeves (32) using J 33792 until the
cups are pushed out of the case (figure 8).
20. Bearings (30) from the sleeves (32). Use J 21551
(figure 9).
21. Pinion flange nut (46) and washer (45) using
J 8614-01 (figure 10).
• Mount the left carrier case half in J 33837-1
(figure 11).
22. Flange (44) and deflector (43) using J 33837-1 and
J 33837-3 (figure 11).
23. Pinion (37), with spacer (40), pinion bearing (39)
and shim (38).
24. Spacer (40) from the pinion.
25. Bearing (39) from the pinion. Use J 22912-01 and
a press (figure 12).
26. Shim (38).
27. Bearing (41) and seal (42) using J 33837-1,
J 33837-3, and J 33837-6.
A. Insert J 33837-6 into the pinion bore.
B. Thread the forcing screw (J 33837-3) into
J 33837-6.
C. Turn the forcing screw to pull the parts from the
case.
28. In n e r b e a rin g cup by p u s h in g it o u t u sin g
J 33837-1, J 33837-3, and J 33837-6 (figure 13).
29. Bolt (36) and shaft (52) from the differential case
(35).
30. Differential pinion gears (56) and thrust washers
(55).
31. Side gears (54) and thrust washers (53).
• Mark the side gears and case so they can be
reinstalled in their original location.
32. Bolts (34).
33. Ring gear (37).
• Do not pry between the ring gear and the case.
Drive the gear off with a brass drift and ham
mer.
34. Side bearings (33), using J 22912-01 (figure 14).
35. Bushings (48). Use J 33791 (figure 15).
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: ......