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IN TER N A L COM PONENTS
[*--►1 Remove or Disconnect (Figures 3 through 23)
Tools Required:
J 22912-01 Gear Puller
J 8433-4 Puller
J 8092 Driver Handle
J 29169 Bearing Remover/Installer
J 33832 Bearing Remover/Installer
J 2619-01 Slide Hammer
J 29369-1 Output Shaft Bearing Remover
1. Speedometer tone wheel (1) from the mainshaft
(23) using J 22912-01 and J 8433-4 (figure 5).
• Be careful not to install J 22912-01 under the
tone wheel snap ring (3).
2. Tone wheel snap ring (3) from the mainshaft (23).
3. Rear output bearing snap ring (4) from the main
shaft (23) using snap ring pliers (figure 6).
4. Case screws (62) from the case halves. Note these
are self-tapping screws and aluminum shavings are
common upon removal.
5. Rear case half (46) from the front case half (31).
• Using a suitable tool, pry between the two pry
bosses to separate the case halves.
6. Clutch coil wire connector (5) from the clutch coil
wire (figure 6).
7. Clutch coil nuts (6) from the clutch coil assembly
(7) (figure 7).
8. Clutch coil (7) from the rear case half (46).
9. Shift rail spring (8) from the shift rail (9).
10. Clutch coil housing snap ring (10) and the clutch
coil housing (11) from the mainshaft (2) using snap
ring pliers (figure 8).
11. S ynchronize r hub (55) from the synchronizer
assembly (12).
12. Synchronizer assembly (12) from the mainshaft
drive gear and mode shift fork (13) from the shift
rail (9) (figure 9).
13. Front output shaft snap ring (15) and flat washer
(17) from the front output shaft (16) (figure 10).
14. Drive gear (18), driven gear (19), and drive chain
(20) as an assembly (figure 11).
15. Front output shaft (16) from the front output bearing
(
22
).
16. Oil pump assembly (66) and mainshaft (23) from
the input carrier (25) and front case half (31) (figure
12
).
17. Shift rail (9), range fork (28), and shift hub (29)
from the input carrier assembly (25) (figure 13).
18. Annulus gear snap ring (30) from the front case
(31) (figure 14).
19. Annulus gear (32) from the front case (31) (figure
15).
20. Input shaft front oil seal (33) from the front case
(31).
21. Carrier assembly snap ring (34) from the carrier
assembly input shaft (25) (figure 16).
22. Input carrier assembly (25) and power take off
drive gear (35) from the front case (31) (figure 17).
23. Retaining clip (36) from the sector shaft (37) (figure
18).
24. Sector shaft (37) from the front case (31).
25. Sector (38), detent spring (39), and detent roller
(49) from the front case (31).
26. Front input bearing snap ring (43) from the front
case (31) (figure 19).
27. Front input bearing (44) from the front case (31)
using J 8092 and J 29169 (figure 20).
28. Rear output bearing (45) from the rear case half
(46) using J 8092 and J 33832.
29. Front output shaft rear bearing (85) from the rear
case (46) using J 2619-01 Slide Hammer and
J 29369-1 Output Shaft Bearing Remover (figure
21
).
30. Front output shaft seal (42) from the front case
(31).
31. Front output bearing snap ring (40) from the front
case (31) (figure 22).
32. Front output bearing (22) from the front case (31)
using J 8092 and J 33832 (figure 23).
33. Rear output shaft seal (47) from the rear bearing
retainer (50).
SYNCHRO NIZER HUB
ASSEMBLY
❖
Disassemble (Figure 24)
1. Synchronizer hub snap ring (51) from the synchro
nizer hub assembly (12).
2. Lockup hub (52) and compression spring (53) from
the lockup collar (54).
OIL PUM P ASSEMBLY
Disassemble (Figure 24)
❖
• Mainshaft from oil pump assembly.
1. Oil pump cover screws (64) and oil pump cover
(70) from the oil pump body (66).
2. Oil pump drive gear (67) and driven gear (68) from
oil pump body (66).
3. Retainer (71) from the pick up tube (72).
4. Pick up tube (72) and oil pump pickup (26) from
the oil pump body (66).
5. Oil pump pickup (26) from the pick up tube (72).
6. Needle bearings from (19) mainshaft.
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: ......