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51. Synchronizer Hub Snap Ring
52. Lockup Hub Assembly
53. Compression Spring
54. Lockup Collar
F6624
Figure 24— Synchronizer Hub Assembly
CLEANING AND INSPECTION
Clean
1. Bearings.
2. Shafts.
3. Sprockets.
4. Chain.
5. Oil feed ports and channels in each case half.
Apply compressed air to each oil feed port and
channel in order to remove any obstructions or
cleaning solvent residue.
6. All mating surfaces.
L*
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. Retainer rings for excessive wear, distortion, or
damage.
6. Case halves for damaged or warped mating sur
faces, cracks, porosity, or damaged thread holes,
7. Synchronizer assembly for cracks, chips, spalling,
or excessive wear.
8. Synchronizer hub and sleeve for cracks, chips,
spalling, or excessive wear.
9. Pads on the mode fork and the range fork for wear
or distortion.
10. Oil pump gears, housing, and mainshaft for wear,
spalling, cracks, and damage. Replace complete
assembly if there is wear.
11. Input gear, planetary carrier, and range shift hub
tooth chamfers for excessive wear.
ASSEMBLY
During assembly of the transfer case, lubricate all
necessary parts with Dexron II E automatic transmis
sion fluid, or equivalent.
O IL PUM P ASSEMBLY
y
Assemble (Figure 24)
1. Needle bearings (19) to mainshaft.
2. Oil pump pickup (26), to the pickup tube (72).
3. Pickup tube (72), oil pump pickup (26), and retainer
(71) to the oil pump body (66).
4. The oil pump drive gear (67) and driven gear (68)
into oil pump body (66).
• Lubricate the assembly with automatic transmis
sion fluid.
N O T IC E : R e f e r to
“
N o t i c e " o n p a g e 7 D 6 -1 .
5. Oil pump cover (70) and oil pump cover screws
(64) to oil pump body (66).
Tighten
L*
Pump cover screws (64) to 2.5 N.m (22 lbs. in.).
Inspect
Oil pump operation on the mainshaft. The main
shaft must turn freely within the oil pump. If
binding occurs, remove the cover, rotate the
gears, and reinstall the cover.
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: ......