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UNIT ASSEMBLY
Use new seals, gaskets, and thread sealer on all bolt
threads when assembling the transmission. Tighten all
bolts to specified torque.
Lubricate all assemblies as they are installed in the
transmission using Dexron® HE automatic transmission
fluid oil or equivalent.
DRIVE GEAR ASSEMBLY
Disassemble (Figure 19)
❖
Tools Required:
J 22912-01 Bearing and Gear Puller
J 6133-01 Installer
1. Bearing (99) onto the drive gear (100) using
J 22912-01 with J 6133-01 and a press.
• Coat roller bearings and drive gear bearing bore
with lightweight grease.
2. Roller bearings (101) into the bore of the drive
gear.
3. Thrust bearing (29) and race (30) into the drive
gear.
M A IN SH A FT ASSEMBLY
Disassemble (Figures 1 and 2)
❖
Tool Required:
J 25234 Front and Rear Bearing Installer
J 37360 Spiral Snap Ring Installer
J 37372 Synchronizer and Gear Installer
Important
• If replacing first-second or third-fourth synchronizer
blocker rings, soak new blocker ring assemblies for
10 minutes in Dexron® HE or equivalent before
assembly on mainshaft.
• Coat mainshaft and gear bores with transmis
sion lubricant.
1. First-second synchronizer sleeve (16) on mainshaft
hub.
• Align marks made during disassembly.
Important
4. Locating pin (46) into the main shaft (14).
5. Sleeve (20) and needle bearing (21) into mainshaft,
aligning notch in sleeve with locating pin.
6. First gear (22).
• Align slots in first gear with tabs on blocker ring
assembly.
7. Rear mainshaft bearing (23) with taper facing rear
of shaft.
8. Fifth gear (25) onto mainshaft (14) using J 25234
and a press.
• Lubricate fifth-gear splines with petroleum jelly.
• Carefully align the mainshaft and gear splines.
If splines are improperly aligned, damage could
occur when the gear is pressed onto the main
shaft.
9. Fifth gear snap ring.
10. Three-piece second gear blocker ring assembly
and thrust washer (44).
11. Spiral snap ring (43) using J 37360.
12. Second gear spacer (42), needle bearing (41), and
gear (40).
• Align slots in second gear with tabs on blocker
ring assembly.
13. Second gear thrust washer (39) and snap ring (38).
14. Third gear spacer (37) and needle bearing assem
bly (36).
• Make sure the bearing spacer is not trapped
between the gear face and snap ring. The spac
er runs inside the gear bore.
15. Third-fourth synchronizer, third blocker ring (31),
sleeve (34), hub (32), and third gear (35) as an
assembly using J 37372 and a press.
16. Thrust bearing (29) and race (30) to front front end
of mainshaft.
Important
• Before pressing components together, make sure
the synchronizer hub faces the short end of the
mainshaft. Hold third gear against the synchronizer
to maintain blocker ring alignment with keys.
TR A N SM ISSIO N ASSEMBLY
+<■
Install or Connect (Figures 1 and 2)
• Use care in synchronizer spring placement. If syn
chronizer is assembled with improper spring place
ment, hard shifting will result.
2. First-second synchronizer keys (45) and springs
(15).
• Engage tang end of each spring in the same
synchronizer key, but position open end of
springs opposite of each other.
NOTICE: F o r s te p s 5, 17, 20, 23, 29, 30, a n d
32, re fe r to “ N o tic e ” on p a g e 7B3-1.
Tools Required:
J 3 7 3 5 7 C o u n te rs h a ft B e a rin g and R ace
Remover and Installer
J 8092 Universal Driver Handle
J 37372 Synchronizer and Gear Installer
J 8001 Dial Indicator
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: ......