![background image](http://html1.mh-extra.com/html/gmc/s-series-1994/s-series-1994_repair-manual_2235929210.webp)
CLEANING AND INSPECTION
CLEANING
Do not steam clean drive parts having ground and
polished surfaces such as gears, bearings, and shafts.
All parts should be disassembled before cleaning.
These parts should be cleaned in a suitable solvent.
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may be
dried with compressed air. Do not allow the bearings to
spin while drying them with compressed air.
INSPECTIO N
It is critical to carefully and thorough ly inspect all
drive unit parts before assembly.
Thorough inspection of the drive parts for wear or
stress and subsequent replacement of worn parts will
eliminate costly drive component repair after reassem
bly.
AXLE HOUSING
Inspect
• Axle housing bore for nicks or burrs that would
prevent the outer diameter of the pinion seal from
sealing. Remove any burrs that are found.
• Bearing cup surfaces for nicks or burrs. Remove
any burrs that are found.
• Housing for cracks. Replace the housing if any
cracks are found.
• 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, spalling.
• Thrust washers for wear.
• The fit of the side gears in the differential case.
• Fit of the side gear on the axle shafts.
• Differential case for cracks and scoring.
• All parts for wear and replace if necessary.
RING AND PINION GEAR
• Ring and pinion gears are matched sets and both
are replaced any time a replacement of either is
necessary.
Inspect
Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.
Pinion splines for wear.
Pinion flange splines for wear.
The fit of the pinion gear on the pinion flange.
• The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause dam
age to the seal’s inside diameter and result in an
oil leak.
• All worn or broken parts and replace if necessary.
9
Important
A new pinion flange must be replaced when the
ring gear and pinion gear are replaced to maintain
proper system balance.
BEARINGS
L*
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 replace them in sets.
• Low m ile a g e be a rin g s m ay have ve ry sm all
scratches and pits on the rollers and bearing cups
from the initial preload. Do not replace a bearing
for this reason.
THRUST WASHERS, SHIMS, AND ADJUSTER
SLEEVES
13
Inspect
Shims and thrust washers for cracks and chips.
Dam aged shim s should be replaced with an
equal-size service shim.
Adjuster sleeves for damaged threads. Replace if
required.
SHIFT MECHANISM
Inspect (Figure 1)
Carrier connector (9) for damaged splines and
teeth. Replace as required.
Shift fork (17) for wear, scoring, and damage to
thrust surfaces. Replace if needed.
Sleeve (22) and inner output shaft (23) for dam
aged splines and teeth. Replace if necessary.
Spring (16) for breakage.
Important
Lubricate all seal lips, bearings, gears, and bearing
surfaces with axle lubricant prior to assembly.
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: ......