CLEANING AND INSPECTION
Clean
1. Bearings.
2. Shafts.
3. Sprockets.
4. Chain.
5. Oil feed ports and channels. Apply compressed air
to each oil feed port and channel in order to
remove any obstructions or cleaning solvent resi
due.
Inspect
1. Bearings and thrust washers for wear, spalling,
brinelling, or corrosion.
2. Gear teeth for excessive wear or damage, spalling,
cracks, or corrosion.
3. Gear splines for excessive wear, spalling, cracks,
twist, or corrosion.
4. Shaft splines for excessive wear, spalling, cracks,
distortion, or corrosion.
5. Case half for damaged or warped mating surfaces,
cracks, porosity, or damaged thread holes.
6. Oil scoop on the output shaft assembly for cracks,
wear, or damage.
7. Speedometer tone wheel (37) for wear, spalling,
cracks, twist, and corrosion.
8. Speed sensor and the breather assembly O-ring
seals for cuts, tears, cracks, or damage.
ijjji
ASSEMBLY
Tools Required:
J 7079-2 Driver Handle
J 38212 Needle Bearing Installer
J 38423 Front Output Shaft Front Bearing Installer
J 8092 Driver Handle
During assembly of the transfer case, lube all neces
sary parts with Dexron® II E Automatic Transmission
Fluid or (GM P\N 9985286).
*
Assemble (Figures 12 through 17)
1. Viscous clutch (20), drive sprocket (17), drive
sprocket spacer (16), and the sun gear shaft bear
ing (33) onto the sun gear shaft (18) (figure 12).
2. Input shaft pilot bearing (38) into the output shaft
assembly (24) using J 7079-2 and J 38212 (figure
13).
3. Output shaft assembly (24) to the gear ring (30).
4. Gear ring snap ring (29) to the gear ring (30) (fig
ure 14).
5. Output shaft bearing (35) to the front cover (11)
using J 8092 and J 38423.
6. Output shaft bearing snap ring (34) to the front
cover (11) (figure 16).
7. Output shaft rear bearing (39) to the rear case half
(10) using J 7079-2 and J 38212 (figure 17).
Install or Connect (Figures 4 and 18 through 25)
N O T IC E : F o r s t e p s 4 , 5 , 18, a n d 2 2 , r e f e r to
“ N o t i c e ” o n p a g e 7 D 5 -1 .
Tools Required:
J 37668 Seal Installer
J 38216 Seal Installer
1. Output shaft assembly (24) and gear ring (30)
through the rear case half (10).
2. Output shaft bearing snap ring (27) to the output
shaft bearing (28) (figure 18).
3. Apply an 1/8-inch bead of RTV sealer (GM P/N
1052366) or equivalent to the rear case half (10)
extension housing sealing surface.
4. Extension housing (8) and the extension housing
bolts (25) to the rear case half (10).
17
20
16. Drive Sprocket Spacer
17. Drive Sprocket
18. Sun Gear Shaft
20. Viscous Clutch
33. Sun Gear Shaft Bearing
F7603
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: ......