Inspection

INSPECT

- Tools Required:
- J 26900-2 Micrometer
- J 8001 Dial Indicator
- J 26900-13 Magnetic Base
- J 33183 Input Shaft Seal Installer
- J 23907 Slide Hammer
- J 29369-1 Input Shaft Front Bearing Puller
- J 29369-2 Shaft Front Bearing Puller
- J 35656 Input Shaft Front Bearing Installer
- J 35657 Shaft Front Bearing Installer
- J 8092 Universal Driver Handle
- J 35553 Differential Side Bearing Seal Installer
- J 35399 Differential Side Bearing Cap remover
- J 35552 Differential Side Bearing Cap Installer





1. Measure the outer diameter of the input shaft journal surfaces with a J 26900-2 micrometer.
- Minimum outer diameter:
A. 24.87 mm (0.9791")
B. 28.97 mm (1.1405")
C. 30.97 mm (1.2193")
D. 24.97 mm (0.9831")

Important
- If any of the journal surfaces are under specifications, the input shaft must be replaced.





2. Input shaft runout using a J 8001 dial indicator and a J 26900-13 magnetic base. If runout exceeds 0.05 mm (0.0020 inch), replace the input shaft.





3. Output shaft using a J 26900-2 micrometer. Measure the outer diameter of the output shaft journal surfaces.
- Minimum outer diameter:
A. 32.97 mm (1.2980") .
B. 37.97 mm (1.4949") .
C. 31.97 mm (1.2587") .

Important
- If any of the journal surfaces are under specifications, the output shaft must be replaced.





4. Output shaft runout using a J 8001 dial indicator and a J 26900-13 magnetic base. If runout exceeds 0.05 mm (0.0020 inch), replace the output shaft.
5. Synchronizer rings by turning and pushing them in to check the braking action.





6. Synchronizer ring clearance by measuring between the synchronizer ring back and the gear spline end. If clearance is less than 0.6 mm (0.024 inch), replace the synchronizer ring.





7. Using a feeler gage, measure the clearance between the hub sleeve and the shift fork. If the clearance exceeds 1.0 mm (0.0039 inch), replace the shift fork or hub sleeve.
8. Remove the input shaft front seal.
9. Remove the bearing lock plate.








10. Input shaft front bearing. If it is necessary to replace the bearing, use a J 23907 slide hammer and a J 29369-1 puller. Install the bearing using a J 8092 driver handle and a J 35656 installer.








11. Output shaft front bearing. If it is necessary to replace the bearing, use a J 23907 slide hammer and J 29369-2 puller. Install the bearing using a J 8092 driver handle and a J 35657 installer.
12. Install the input shaft front seal using a J 33183 installer. Lightly coat the seal lip with GM # 1051344.
13. Install the bearing lock plate.

Tighten
- Bearing lock bolts to 11 N.m (97 lb. in.).





14. RH differential oil seal. If replacement is necessary, remove the.seal with a screwdriver. Using a J 35553 seal installer, install a new seal flush with the case surface. Lightly coat the seal lip with GM # 1051344.
15. LH differential oil seal. If replacement is necessary, remove the seal with a screwdriver. Using a J 35553 seal installer, install a new seal flush with the case surface. Lightly coat the seal lip with GM # 1051344.





16. RH and LH differential bearing caps. If replacement is necessary, remove the bearing caps with a J 35399 cap remover. Install the bearing caps with a J 35552 cap installer.
17. Control shaft cover seal. If replacement is necessary, remove the old seal with a screwdriver and tap in a new seal. Coat the lip of the seal with GM # 1051344.





18. Speedometer seal. If replacement is necessary, remove the old seal and coat the new seal with GM # 1051344 and install to a depth of 25 mm (0.98 inch).
19. Reverse restrict pin. If replacement is necessary, perform the following procedures:
a. Remove the reverse restrict holder.
b. Using a pin punch and hammer, driver out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Driver in the slotted pin.