Chevrolet 1977 10 Series, Repair Manual, Page: 88 / 468

4B-16
OVERHAUL MANUAL
DIFFERENTIAL CASE
Removal and Disassembly
N O T E : Before p ro c eed in g w ith follow ing
steps, it is advisable to check the existing rin g
gear to p in io n backlash as described u n d e r
"C hecks and A d ju stm en ts". T his will in dicate
gear or bearin g w ear o r an e rro r in backlash
o r p in io n depth settin g w hich will help in
d eterm in in g cause o f axle noise. Backlash
should be recorded so th a t if sam e gears are
reused, they m ay be re in stalled at o rig in al
lash to avoid ch an g in g g e a r tooth contact.
1. Rem ove screw th at re ta in s differen tial p in io n sh aft,
and rem ove pinion sh aft.
2. Rem ove re a r axle sh afts as ou tlin ed in the Service
M anual.
3. Roll out the differential p in io n s and th ru st w ashers,
th e n rem ove side gears a n d th ru st w ashers. M ark
p in io n s and side gears so th a t they can be
reassem bled in o rig in al position.
4. M ark the b earin g caps and housing fo r reassem bly
in sam e position. Loosen b earin g cap bolts. T ap
surface o f b earin g caps to loosen.
CAUTION:
Do not attempt to pry caps o ff as
this may damage machined face o f caps.
5. U sing a pry b ar as show n in F ig u re 2B, pry
differential case out o f c a rrier. Exercise caution in
p ry in g on carrie r so th a t gasket sealing surface is
not dam ag ed . If the b e a rin g s are p relo ad ed , the
case will suddenly fall free w hen it is p ried p ast a
certa in point; th erefo re, m ake sure case is p ro p erly
su p p o rted to p rev en t d am ag e. T he b e arin g caps
m ay be loosely installed, as shown in F ig u re 2B, to
prev en t case from falling.
6. Place left an d rig h t b e a rin g cups w ith b e a rin g caps
so th at they m ay be rein sta lled in o rig in al positions.
Place shim s w ith a p p ro p ria te cups.
Inspection
1. C lean all p arts in clea n in g solvent; inspect all
b earin g cups, races and rollers for scoring, chipping
or evidence o f excessive w ear.
2. Inspect axle sh a ft and side g e a r splines fo r evidence
o f excessive w ear.
3. Inspect hypoid rin g g e a r an d p in io n teeth for
possible scoring, cracking o r chipping.
4. Inspect differential case, p in io n s, side gears, th ru st
w ashers and p in io n sh a ft fo r cracks, scoring,
spalling or excessive w ear.
5. Check fit o f differential side gears in case.
Differential Bearing Replacement
1. Install Tool J-22888 an d A d a p te r Plug J -8 107-4,
assuring puller legs are fitted securely in notches in
case and ag ain st b e a rin g cone, as show n in figure
3B.
2. T ighten pu ller screw to rem ove b earing.
3. Place new b e arin g on hub w ith thick side o f in n er
race tow ard case an d drive in to place, using J-22175
and D riv er H andle J-8092, as show n in figure 4B.
4. B efore b e a rin g in s ta lla tio n on o p p o site hub,
support differential case on A d a p te r Plug J -8 107-4.
T his allows d ifferential case to rest on ad a p te r
instead o f b e arin g cage. See Figure 4B. Install
re m ain in g b e a rin g as in stru cted in Step 3.
Ring Gear or Differential Case Replacement
1. Rem ove the rin g g ea r bolts (L.H. th re a d on
passenger car ap p licatio n s) an d , using a soft d rift
and a h am m er, ta p rin g g e a r off the case.
N O T E : D o not atte m p t to p ry rin g g ear from
case. To do so m ay d a m a g e m achined
surfaces.
2. Rem ove any nicks or im b e d d e d d irt from case
Fig. 2B—Differential Case Removal Fig. 3B—Differential Bearing Removal
J 2 2 8 8 8
OVERHAUL MANUAL