chevrolet truck Light Duty Truck 1994 Series, Repair Manual

Page: 205 / 919

DISASSEMBLY
Disassemble (Figure 1 through 15)
Tools Required:
J 2619-01 Slide Hammer
J 29369-2 Seal Remover
J 8614-01 Pinion Flange Remover
J 21551 Bearing Remover
J 22912-01 Pinion Bearing Cone Remover
J 29307 Slide Hammer
J 33791 Bushing Remover
J 33792 Side Bearing Adjuster Wrench
J 33837 Pinion Bearing Cup Remover Kit
J 34011 Output Shaft Pilot Bearing Remover
1. Bolts (6), shift cable housing (11), and spring (14).
2. Tube (5), and thrust washer (7).
3. Spring (16), and shift shaft with fork (17).
4. Axle shaft (1) with deflector (2).
A. Clamp the axle tube (5) in a vise. Clamp ONLY
on the mounting flange.
B. Strike the inside of the shaft flange with a brass
hammer to dislodge the shaft.
5. Carrier connector (9) with retaining ring (8).
6. Right seal (3) and bearing (4), using J 29369-2 and
J 29307 (figure 3).
7. Seal (15) from the tube (5). Pry out with a screw­
driver.
8. Thrust washer (20).
9. Sleeve (22) and output shaft (23).
10. Differential pilot bearing (21) from the output shaft,
using J 34011 (figure 4).
11. Washer (24).
12. Shaft (59), and deflector (2).
• Using J 2619-01, pull the output shaft out of the
case (figure 5).
13. Bolts (58) and cover (57).
14. Left seal (3).
15. Bolts (28).
16. Separate the carrier case (29).
• Insert a screwdriver into the slots provided and
pry to separate the case (figure 6).
17. Differential case (35).
18. Bolts (18) and lock tabs (19) from the side bearing
adjuster sleeves (32) (figure 7).
19. Bearing cups (33) and sleeves (32) from the case.
• Turn the sleeves (32) using J 33792 until the
cups are pushed out of the case (figure 8).
20. Bearings (30) from the sleeves (32). Use J 21551
(figure 9).
21. Pinion flange nut (46) and washer (45) using
J 8614-01 (figure 10).
• Mount the left carrier case half in J 33837-1
(figure 11).
22. Flange (44) and deflector (43) using J 33837-1 and
J 33837-3 (figure 11).
23. Pinion (37), with spacer (40), pinion bearing (39)
and shim (38).
24. Spacer (40) from the pinion.
25. Bearing (39) from the pinion. Use J 22912-01 and
a press (figure 12).
26. Shim (38).
27. Bearing (41) and seal (42) using J 33837-1,
J 33837-3, and J 33837-6.
A. Insert J 33837-6 into the pinion bore.
B. Thread the forcing screw (J 33837-3) into
J 33837-6.
C. Turn the forcing screw to pull the parts from the
case.
28. In n e r b e a rin g cup by p u s h in g it o u t u sin g
J 33837-1, J 33837-3, and J 33837-6 (figure 13).
29. Bolt (36) and shaft (52) from the differential case
(35).
30. Differential pinion gears (56) and thrust washers
(55).
31. Side gears (54) and thrust washers (53).
• Mark the side gears and case so they can be
reinstalled in their original location.
32. Bolts (34).
33. Ring gear (37).
• Do not pry between the ring gear and the case.
Drive the gear off with a brass drift and ham­
mer.
34. Side bearings (33), using J 22912-01 (figure 14).
35. Bushings (48). Use J 33791 (figure 15).