Chevrolet 1977 Monte Carlo, Repair Manual

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REAR AXLE DIFFERENTIAL 4B-47
1. Differential Case Bolt
2. Differential
Case-P lain Half
3. Differential
C ase-Flanged Half
5.
Friction P late-T abb ed
(Belleville)
Friction D isc-Toothed
(Belleville)
6. Friction P late -T a b b ed
(Flat)
7. Friction D isc-Toothed
(Flat)
8. Side Gear Ring
9. Side Gear
10. Pinion Gears
11. Cross Shafts
F ig . 2 2 D - P o w e r - L o k D if f e r e n t i a l
be corrected by grinding 1/32" o ff the end o f the axle shaft.
2. Inspect clutch discs and plates for wear, cracked, or
distorted condition.
3. Inspect side gear rings, side gears, and differential
cases for worn, cracked, or distorted condition that would
render these parts unfit for further services.
A ssem bly
D uring assembly operations, all parts should be kept
clean and free o f dirt or other foreign material. A s each part
is assembled in its proper position, it is necessary that it be
lightly coated with the correct lubricant.
1. Place tabbed Belleville friction plate (4) in flanged
differential case, being extrem ely careful that convex
(bulged) side is toward the side gear. See figure 22D .
2. A ssem ble rem aining plates and discs to splines o f
side gear ring, being sure they are assem bled in the same
order o f removal. The convex (bulged) side o f the Belleveille
friction disc (5) should be toward the side gear and it should
nest into the Belleville friction plate (4).
3. Place assem bled side gear ring with plates and discs
in flanged h alf o f differential case.
4. Install side gear and cross shafts with pinions.
5. In the order listed install the following: (1) side gear,
(2) side gear ring, (3) flat plate with tabs, (4) flat disc with
teeth, (5) flat plate with tabs, (6) B elleville disc with convex
(bulged) side up, or toward side gear, (7) B elleville plate,
with convex (bulged) side up, or side toward gear.
6. Position plain h alf o f differential case over previously
assem bled parts with scribe m arkings on both halves o f case
in alignm ent.
7. Install differential case bolts, but do not tighten at
this time.
8. Before tightening bolts, use axle shafts and align
splines o f the side gear and side gear ring, on each side.
Tighten bolts evenly and alternately. R em ove axle shafts.
9. Observe if Pow er-L ok com ponents have been
assem bled properly. Each pinion cross shaft can be tight on
its ramp or if there is clearance it should be only a few
thousandths, and it should be equal at all four cross shaft
ends.
Testing Procedure
The Pow er-L ok can be effectively tested for correct
operation by placing one rear wheel on good dry pavem ent
and the other on ice, snow, mud, gravel, grease, etc.
It can easily be determined whether or not the non­
slipping wheel is providing pulling power. The procedure
should then be repeated with the opposite w heels on the dry
and slippery surfaces.
The above testing procedure is a rough test that can
be m ade by the ow ner o f the vehicle. H ow ever, if it is
suspected that the unit is not operating properly, it can be
checked by the follow ing procedure.
Be sure the transm ission is in neutral. R aise one wheel
o ff the floor and place a block in the front and rear o f the
opposite wheel. R em ove the hub cap and install a special
tool across two wheel studs. A pply a torque wrench to
O V E R H A U L M A N U A L