SECTION 4C2
8 1/4 AND 9 1/4-INCH RING GEAR
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread locking compound will be called o u t
The correct torque value m ust be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
SUBJECT
PAGE
General D escription..................................................................................................................................................... 4C2- 2
Disassembly of the A x le ............................................................................................................................................ 4C2- 2
In sp ectio n ....................................................................................................................................................................4C2- 2
D isassem b ly............................................................................................................................................................... 4C2- 2
C lean in g ....................................................................................................................................................................... 4C2- 3
In sp ectio n ....................................................................................................................................................................4C2- 3
Axle H o u sin g ..........................................................................................................................................................4C2- 3
D ifferential............................................................................................................................................................... 4C2- 3
Pinion and Ring G ear.......................................................................................................................................... 4C2- 3
B e a rin g s .................................................................................................................................................................. 4C2- 3
Shims, Thrust Washers, and Adjuster S leeves........................................................................................... 4C2- 5
Shift M echanism .................................................................................................................................................... 4C2- 5
Actuator Check...................................................................................................................................................... 4C2- 5
Assem bly of the A x le .................................................................................................................................................. 4C2-10
Pinion Bearing Cup Installatio n ........................................................................................................................... 4C2-10
Pinion Depth A d ju stm en t....................................................................................................................................... 4C2-10
Pinion Installation..................................................................................................................................................... 4C2-11
Differential Case A ssem bly....................................................................................................................................4C2-13
Differential Assembly Installation......................................................................................................................... 4C2-13
Adjusting B ac k la s h .................................................................................................................................................. 4C2-15
Measuring B acklas h ............................................................................................................................................ 4C2-15
G ear Tooth Contact Pattern C heck..................................................................................................................... 4C2-15
G ear Tooth T e rm s ................................................................................................................................................. 4C2-15
Test............................................................................................................................................................................ 4C2-16
Adjustments Affecting Tooth C ontact.............................................................................................................4C2-16
Carrier Case A ssem bly........................................................................................................................................... 4C2-16
Axle Tube A s s e m b ly ................................................................................................................................................4C2-16
A ssem bly................................................................................................................................................................. 4C2-16
Output Shaft Shim Selection............................................................................................................................. 4C2-16
Final A s s em b ly..........................................................................................................................................................4C2-18
Drive Axle A ssem b ly................................................................................................................................................... 4C2-21
Outer Deflector Ring R eplacem ent..................................................................................................................... 4C2-21
ABS Sensor Ring Replacem ent............................................................................................................................ 4C2-21
Outer Joint Seal Replacem ent.............................................................................................................................. 4C2-21
Outer Joint Assembly R eplacem ent................................................................................................................... 4C2-24
Inner Tripot Seal R eplacem ent............................................................................................................................. 4C2-25
S p ecificatio n s................................................................................................................................................................ 4C2-28
Fastener Tightening Specifications......................................................................................................................4C2-28
Available Shim Sizes................................................................................................................................................4C2-28
Pinion Preload and B a c k la s h ............................................................................................................................... 4C2-28
Lubrication.................................................................................................................................................................. 4C2-28
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: ......