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3. Synchronizer sleeves for:
• A sliding fit on the synchronizer hubs and for
the hubs to have a force fit on the mainshaft
splines. Replace the hub(s) if they do not
require a force fit on the mainshaft.
4. Synchronizer springs and keys for:
• Damage.
5. Synchronizer rings for:
• Excess wear.
6. Synchronizer clutching teeth for:
• Wear.
• Scuffed.
• Nicked.
• Burred or broken teeth.
7. Speed gear clutching cones for:
• Synchronizer ring metal transfer.
8. All gear teeth for:
• Excess wear.
— The black phosphate coating will develop
wear patterns. This is a normal condition.
9. Bearings and bearing surfaces for:
• Nicks.
• Burrs.
• Bent cages.
• Wear.
10. Lubricate all bearings and check for rough rotation.
• If scuffed, nicked, burred, scoring, or synchro
nizer ring metal transfer conditions cannot be
removed with a soft stone or crocus cloth,
replace the com ponent and inspect mating
parts.
• Lubricate all components as assembly progres
ses. Use lubricant 5W-30 GM P/N 1052931 or
equivalent.
COUNTERSHAFT
Clean (Figure 31)
• All parts in a suitable solvent and air dry.
Inspect (Figure 31)
1. Shaft (53) for cracks. Replace if these conditions
exist.
2. Gear teeth (53) for scuffed, nicked, burred, broken
teeth, or high spots (a small shiny spot on the gear
teeth mating surface) that could cause gear noise.
3. Bearings (35) for roughness of rotation, burred, or
pitted condition. Replace if these conditions exist.
4. Bearing races (202) for scoring, wear, or overheat
ing.
• If scuffed, nicked, or burred conditions cannot
be removed with a soft stone or crocus cloth,
replace the component.
• Fifth gear CANNOT be pressed off the counter
shaft assembly (53). Replace as an assembly
only.
REVERSE IDLER GEAR
Clean
I?
• All parts in a suitable solvent and air dry.
Inspect
1.G ear teeth for scuffed, nicked, burred, broken
teeth, or high spots (a small shiny spot on the gear
teeth mating surface) that could cause gear noise.
2. Bearing assembly for roughness of rotation, burred,
or pitted condition and cage damage. Replace if
these conditions exist
3. Shaft, for scoring, wear, or overheating.
• If scuffed, nicked or burred conditions cannot
be removed with a soft stone or crocus cloth,
replace the component.
FRONT AND REAR H O USING S
Inspect
1. Bearing race bore, for wear, scratches, or grooves:
if counter shaft bearing race bore is worn or dam
aged the rear housing MUST be replaced.
2. Bushings, for scores, burrs, roundness, or evidence
of overheating.
Important
• O utput shaft bushing cannot be serviced.
Replace the rear housing if the bushing is worn
or damaged (2WD models only).
3. Case for cracks, threaded opening for damaged
threads, m ounting faces for nicks, burrs, or
scratches; if case is cracked, it must be replaced.
4. Machined mating surfaces for flatness. Check with
a straight edge.
Important
• If scratches, grooves, or scoring cannot be
removed with a soft stone or crocus cloth,
replace the component.
• Clean up dam aged threads with correct size
tap.
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: ......