SECTION 4C3
ALL WHEEL DRIVE FRONT AXLE
7 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) m ay
be used. Fasteners that are not reused, and those requiring thread locking compound will be called out.
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......................................................................................................................................................4C3- 2
Disassembly of the A x le .............................................................................................................................................4C3- 2
In sp ectio n .................................................................................................................................................................... 4C3- 2
D isassem bly............................................................................................................................................................... 4C3- 2
C lean in g ....................................................................................................................................................................... 4C3- 4
In sp ectio n .................................................................................................................................................................... 4C3- 4
Axle H o u sin g .......................................................................................................................................................... 4C3- 4
D ifferential............................................................................................................................................................... 4C3- 5
Ring and Pinion G ears........................................................................................................................................ 4C3- 5
B e arin g s...................................................................................................................................................................4C3- 5
Thrust Washers, Shims, and Adjuster S le e v e s ........................................................................................... 4C3- 6
Assembly of the A x le .................................................................................................................................................. 4C3- 7
Differential Case A ssem bly.................................................................................................................................... 4C3- 7
Pinion Bearing Installation..................................................................................................................................... 4C3- 8
Pinion Depth A d ju stm en t....................................................................................................................................... 4C3- 8
Pinion Installation......................................................................................................................................................4C3- 8
Differential Case Installation..................................................................................................................................4C3-10
Adjusting B ac k la s h .................................................................................................................................................. 4C3-10
Gear Tooth Contact Pattern C h e c k ......................................................................................................................4C3-12
Gear Tooth Nom enclature................................................................................................................................... 4C3-12
Test.............................................................................................................................................................................4C3-12
Adjustments Affecting Gear Tooth C o n tact......................................................... ........................................ 4C3-12
Final A s s e m b ly .......................................................................................................................................................... 4C3-12
Drive Axle A s s em b ly.......................................................................................................... ........................................ 4C3-14
Outer Deflector R in g ................................................................................................................................................ 4C3-14
ABS Sensor Ring.......................................................................................................................................................4C3-14
Outer Joint S e a l......................................................................................................................................................... 4C3-16
Outer Joint A ssem bly..............................................................................................................................................4C3-17
Inner Tripot S e a l........................................................................................................................................................ 4C3-19
S p ecificatio n s.................................................................................................................................................................4C3-21
Fastener Tightening Specifications......................................................................................................................4C3-21
Available Shim S izes................................................................................................................................................ 4C3-21
Pinion Preload and B a cklas h ................................................................................................................................4C3-21
Lubrication...................................................................................................................................................................4C3-21
Special T o o ls ..................................................................................................................................................................4C3-22
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: ......