chevrolet truck Light Duty Truck 1994 Series, Repair Manual

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The differential allows the wheels to turn at different
rates of speed while the axle continues to transmit the
driving force. This prevents tire scuffing on turns and
premature wear on internal axle parts.
The axle is sealed with a pinion seal, a seal at each
axle shaft end, and RTV sealant between the cover and
axle housing.
All corporate rear axles are identified by an alphabetic
broadcast code on the right axle tube near the carrier.
The axle housing cover does not have a drain plug.
C H EC K IN G TH E AXLE
BEFORE DISASSEM BLY
Remove the housing cover and drain the lubricant.
L9
Inspect
1. Ring gear backlash. Refer to “ Backlash Adjust­
ment.” This information can be used to determine
the cause of the problem. It will also help when
setting up the shim packs for locating and preload­
ing the differential case.
2. Case for metal chips and shavings. Determine
where these chips and shavings came from, such
as a broken gear or bearing cage.
• Determine the cause of the axle problem before
disassembly if possible.
DISASSEMBLY OF THE
REAR AXLE
+-► Remove or Disconnect (Figures 1 through 9)
Tools Required:
J 8107-3 Differential Side Bearing Puller Plug
J 22813-01 Axle Bearing Remover
J 2619-01 Slide Hammer
J 22888 Differential Side Bearing Remover
J 8614-01 Pinion Flange Remover
J 22910-01 Rear Pinion Bearing Cone Remover
• Place the axle in a suitable support.
• Drain the lubricant.
1. The cover bolts (24) and cover (25).
• Refer to “ Checking the Axle Before Disassem­
bly.”
2. Pinion shaft lock bolt (29) (figure 2).
3. Pinion shaft (28).
4. “ C” clip (37) from the end of the axle shaft (3).
• Push the axle shaft (3) in towards the center of
the differential case (27).
5. Axle shaft (3) from the axle housing (12).
6. Oil seal (4) using a seal removal tool behind the
seal lip.
• Be careful not to damage the housing.
7. Bearing (5) using J 2619-01 and J 22813-01.
• The tangs of the tool should engage the bear­
ing outer race.
8. Pinion (31) and side gears (33).
A. Roll the pinion gears out of the case with the
pinion thrust washer (30).
B. Remove the side gears (33) and the side gear
thrust washers (32). Mark the gears and the
differential case as left and right.
9. Lock bolt (18).
10. Lock (16).
• Loosen the adjusting nut (17).
11. Bearing cap bolts (20).
12. Bearing caps (19).
• Mark the caps and the housing as left and right.
NOTICE: When prying the differential case
out o f the axle housing, be careful not to
damage the cover gasket surface. The differ­
ential case m u st be supported when it is
being removed to prevent the case from fall­
ing and damaging the case.
13. Differential case (27).
• Pry the case from the axle housing at the differ­
ential “ window” (figure 3).
14. Bearing outer races (22), shims (21), and adjusting
nut (17).
• Mark the races and the shims as left and right,
and place them with the bearing caps.
15. D ifferential side bearings using J 8107-3 and
J 22888 (figure 4).
• The jaws of J 22888 must pull from beneath the
bearing cone and not the cage. Use the slots
provided for this purpose.
16. Ring gear bolts (26).
• Ring gear bolts have left-hand threads.
NOTICE: Do not pry the ring gear from the
case. This will damage the ring gear and the
differential case.
17. Ring gear (15) from the differential.
• Drive the ring gear off with a brass drift if nec­
essary.
I?
Inspect
Drive pinion bearing preload (figure 5).
Pinion assembly for looseness by moving it
back and forth. Looseness indicates excessive
bearing wear.