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1. Countershaft (52) into case (67).
2. Rear countershaft bearing (51) to countershaft
using J 37372 and a press (figure 34).
• Support the countershaft with J 37357.
Important
• Failure to properly support the countershaft may
result in permanent distortion of the case during
installation.
3. Rear countershaft bearing race (53).
4. Reverse idler gear (70) and the shaft (72).
• Hold the gear in the case with the shift lever
groove to the rear.
• Install the reverse idler shaft from the rear.
• Install a new retaining pin (71).
5. Countershaft retainer (55) to transmission housing
without shims.
Tighten
•C ountershaft retainer bolts to 20 N-m (15 lbs.
ft.).
Measure
• C ountershaft end play using dial indicator
J 8001 (figure 35).
• Remove retainer and install shim(s) as neces
sary to provide proper end play. Zero end play
with no preload is ideal, but up to 0.10 mm
(0.004 inch) end play is allowable. Do not
preload bearing with shim(s) larger than original
end play measurement.
• Reinstall retainer (55) and bolts (56).
Tighten
• Retainer bolts (56) to 20 N-m (15 lbs. ft.).
• Bend tabs over the four attaching bolts.
6. Reverse shift fork in the case.
7. Mainshaft (14) into the transmission case.
8. Rear mainshaft bearing race (24).
9. Drive drive gear in case (100).
• Make sure rollers, thrust bearing, and washer
are in place.
• Be sure to engage the third-fourth synchronizer
sleeve and blocker ring.
10. Front bearing race (99) in the front bearing retainer
(96).
• Do not install shims in front bearing retainer at
this time.
11. Temporarily install front bearing retainer (96).
• Be sure to align the marks made during disas
sembly.
12. Fifth gear (57) on countershaft.
• Slide shift rail and fifth gear shift fork assembly
into case.
• Align reverse shift fork and slide rail (75)
through fork.
• Position lever return spring in case with long
end of spring to the rear, and slide rail through
the spring (68).
13. Blocker ring (58) and fifth gear synchronizer (62) in
fifth gear shift fork (73).
• Slide fork rail assembly and synchronizer into
position.
14. Fifth gear synchronizer retainer (63) and snap ring
(64) (figure 8).
15. Oiling funnel (65) into rear of countershaft (figure
5).
16. Fifth gear and reverse shift lever (77) in the case
(figure 6).
• Make sure reverse shift fork pin and fifth-gear
shift rail pin are engaged with shift lever.
17. Fifth gear and reverse lever pivot bolt (78) and
retaining clip (76).
• Coat pivot bolt threads with pipe sealant GM
P/N 1052080 or equivalent.
£
Tighten
ft.).
• Pivot bolt (76) to 27 N-m (20 lbs.
18. Backup lamp switch (79).
• Coat threads with pipe thread sealant GM P/N
1052080 or equivalent.
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: ......