GMC T Series 1994 Repair Manual page 231

23. Adjuster plug (61) with side bearing cup (33) and
O-ring seal (62) (K3 models). Use J 36615 (figure
10
).
24. Nut (46). Use J 8614-01 to hold the pinion flange
(figure 11).
25. Washer (45).
26. P inion fla n g e (44) w ith d e fle c to r (43). Use
J 8614-01 (figure 12).
• Mount the left carrier case in J 36598. Be sure to
use the adapter plate (J 36598-6) for K1, 2 models.
27. Ring and pinion (37) with shim (38), bearing cone
(39), and spacer (40). Use J 36598 (figure 13).
28. Spacer (40) from the pinion.
29. Pinion bearing (39). Use J 8612-B (K1, 2 models)
or J 36606 (K3 models) and a press (figure 14).
30. Shim (38).
31. Seal (42), and bearing cup and cone (41). Use
J 36598-6 (figure 15).
32. Bearing cup (39). Use J 36598-6 (figure 16).
33. Side bearings (33). Use J 22888-D and J 8107-2
(K1, 2 models) or J 36597 (K3 models) (figure 17).
34. Ring gear bolts (34).
• Ring gear bolts have left-handed threads.
NOTICE: Do not pry the ring gear from the
case. This will damage the ring gear and the
differential case.
35. Ring gear (37) from the differential case.
• Drive the ring gear off with a brass drift.
36. Pin (36) (K1, 2 models). Drive out with a drift and
hammer (figure 18).
37. Bolt (34) (K3 models).
38. Shaft (52).
39. Differential pinion gears (56) and side gears (54).
A. Roll the pinion gears out of the case with the
pinion thrust washers (55).
B. Remove the side gears and the side gear thrust
washers (53). Mark the gears and the differen­
tial case as left and right.
C. Remove spacer (57) (K3 models only).
40. Vent plug (60). Use a 6-point deep socket.
41. Bushings (48). Use J 36616 (figure 19).
CLEANING
• Do not steam-clean drive parts having ground and
polished surfaces such as gears, bearings, and
shafts. All parts should be disassembled before
cleaning. These parts should be cleaned in a suit­
able solvent.
• Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may
be dried with compressed air. Do not allow the
bearings to spin while drying them with com ­
pressed air.
INSPECTION
It is very important to carefully and thoroughly inspect
all drive unit parts before assembly.
Thorough inspection of the parts for wear or stress
and replacement of worn parts will help prevent costly
drive component repair after reassembly.
AXLE HOUSING
I ? Inspect
• Axle housing bore for nicks or burrs that would
prevent the outer diameter of the pinion seal from
sealing. Remove any burrs that are found.
• Bearing cup surfaces for nicks or burrs. Remove
any burrs that are found.
• Housing for cracks. Replace the housing if any
cracks are found.
• Housing for foreign material such as metal chips,
dirt, or rust. Refer to " Cleaning."
DIFFERENTIAL
Inspect
L 9
• Pinion gear shaft for unusual wear.
• Pinion gear and side gear teeth for wear, cracks,
scoring, and spalling.
• Thrust washers for wear.
• The fit of the differential side gears in the differen­
tial case.
• The fit of the side gears on the axle shafts.
• Differential case for cracks and scoring.
• All parts for wear and replace if necessary.
PINION AND RING GEAR
• Ring and pinion gears are matched sets and must
both be replaced any time a replacement of either
is necessary.
Inspect
1?
• Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.
• Pinion gear splines for wear.
• Pinion flange splines for wear.
• The fit of the pinion flange on the pinion gear.
• Sealing surface of the pinion flange for nicks, burrs,
or rough tool marks which would cause damage to
the inside diameter of the pinion seal and result in
an oil leak.
• All parts for wear and replace if necessary.
BEARINGS
Inspect
I?
k .
Bearings for smooth rotation after oiling them.
Bearing rollers for wear.
Bearing cups for wear, cracks, brinelling and scor­
ing.
Important
• When replacing worn or cracked bearings and
cups, make sure to replace bearings in sets.
• Low m ileage bearings m ay have ve ry sm all
scratches and pits on the rollers and the bearing
cups from the initial preload. Do not replace a
bearing for this reason.