Chevrolet 1977 10 Series, Repair Manual, Page: 141 / 468

REAR AXLE DIFFERENTIAL 4B-69
CASE AND DRIVE PINION
Removal
1. D ra in lu b rican t from d ifferen tial, rem ove axle sh aft
as outlined in T ruck Service M an u al. See "A xle
S h a ft R em oval".
2. Rem ove two tru n n io n b e a rin g " U " bolts fro m the
re a r yoke and split the re a r universal jo in t.
N O T E : T he bearings can be left on the
tru n n io n and held in place w ith tape.
3. Swing p ro p eller sh aft to one side an d tie to the
fram e side rail.
4.
Rem ove bolts and lock w ashers w hich re ta in the
c a rrie r assem bly to the axle housing. S u p p o rt the
differential housing w ith a floor ja ck and roll it
from u n d e r truck.
Disassembly
1. M ount c a rrie r assem bly in a bench vise or h o ld in g
fixture.
2. Loosen rin g gear th ru st p a d locknut and rem ove
th ru st pad.
3. R em ove differential ad ju stin g n u t locks and b e a rin g
cap bolts and lock w ashers.
4. M ark b earin g caps an d c a rrie r fo r reassem bly in
sam e position. Rem ove b e a rin g caps and ad ju stin g
nuts by tap p in g on bosses o f caps w ith a soft faced
h a m m e r until caps are free fro m dowels.
CAUTION: Do not attempt to pry cap off as
this may damage machined fa ce o f cap.
5. R em ove differential an d rin g g e a r assem bly from
the carrier.
CAUTION: Exercise care that differential
bearing outer races are not dropped while
removing assembly from carrier.
6. R em ove the bolts w hich a ttac h the p in io n b e a rin g
re ta in e r to the carrier.
7. R em ove the p inion an d b e a rin g assem bly fro m the
c arrier.
N O T E : It m ay be necessary to drive this u nit
from carrier. Use brass d r if t a g a in st pilo t end
o f pinion.
Repairs
Pinion Disassembly
1. C lam p p inion drive flange in bench vise.
2. Rem ove cotter pin, n u t a n d w ash er from end o f
pinion.
3. Rem ove drive flange and b e a rin g re ta in e r assem bly
from pinion.
4. D rive oil seal from re ta in e r. D iscard seal as new
p arts should be used at assem bly.
5. R em ove p in io n re a r b e a rin g sn ap rin g a n d press
b earin g from p in io n , using Tool J - 1453, as shown
in figure 2G .
6. Position drive p in io n in an a rb o r press so th a t the
b earin g is su p p o rted by two pieces o f flat steel stock
as shown in F ig u re 3G . Place flat stock p arallel to
each o th er an d ag ain st p in io n so as to pick up a
large area o f b e a rin g o u te r race. Press p in io n from
b earin g m ak in g sure p in io n is su p p o rted to p revent
dam age w hen rem oved fro m b earin g .
Pinion Inspection
1. W ash all p a rts in clean in g solvent.
2. Inspect p in io n fo r scored, cracked, ch ip p ed o r w orn
teeth.
3. Inspect splines on p in io n sh a ft fo r excessive w ear.
4. Inspect p in io n b e a rin g assem blies fo r roughness,
defects or excessive w ear.
Fig. 2G—P inion Rear B earing Removal
Fig. 3G—Drive Pinion Front Bearing Removal