Chevrolet 1991 Light Duty Truck Repair Manual page 209

ASSEMBLY OF THE DIFFERENTIAL
f»<-j Install or Connect (Figure 1)
1. Left thrust washer (13).
2. Cam unit. Refer to " Cam Unit Assembly" in this
section.
3. Right thrust washer (8).
4. Right clutch plates with guide clips (19).
• Assemble alternately as shown in figure 1.
5. Right side gear (10).
6. Thrust block (17), thrust washer (6), and pinion
gear (7).
• Place the pinion gears into the differential 180
degrees apart.
• Rotate the gears and thrust block into position.
• The open side of the thrust block must face toward
the small window opening.
7. Pinion shaft (18).
8. A new lockscrew (3). Install finger tight.
• Tighten to specifications after installed in the
vehicle.
9. Governor assembly (23) and latching bracket (11).
• The straight end of the latching bracket spring
must be over and outside the governor assem­
bly shaft (figure 8).
10. Stop pin (2) (9 1/2-inch)
• Press the pin flush with the case.
11. Governor bushing (4).
• Use the bushing with a straight hole, not a
tapered hole.
• Press the bushing in far enough to give 0.004
to 0.020-inch shaft end play.
12. Latching bracket bushing (5).
• Press in far enough to eliminate all end play.
LOCKING DIFFERENTIAL 4B7-5
10 1/2-INCH RING GEAR
DISASSEMBLY OF THE DIFFERENTIAL
|<--»| Remove or Disconnect (Figure 9)
Tools Required:
J 22912-01
1. The ring gear and differential side bearings. Refer
to "Disassembly of the Rear Axle" under the "10
1/2-Inch Ring Gear" heading.
2. Case screws (32).
— Set the unit on the right side case half.
3. Case halves (figure 10).
• Pry the halves apart at the yoke hole location.
• Hold the side gear in the left side case half.
4. Governor assembly (48).
5. Latching bracket assembly (43).
6. Left side gear (46).
7. Left side clutch pack and guide clips (47).
8. Left thrust washer (45).
9. Reaction blocks (41), pinion yoke (42), pinion
gears (39), and pinion thrust washers (38).
10. Right cam unit from the differential.
11. Right thrust washer (36).
• Measure and record the overall length of the
gear assembly from the front of the gear to the
back of the thrust sleeve (35) including the side
gear washer (36).
12. Thrust sleeve (35) using J 22912-01.
• Press the sleeve from the side gear (figure 11).
13. Clutch plates.
14. Guide clips (34).
15. Wave spring.
16. Cam plate (33).
17. Cam side gear (40)
CLEANING AND INSPECTION
pQ*| Clean
• All parts with solvent.
|L « | Inspect
• All parts for excessive wear and breakage.
• Pinion gear and side gear teeth for wear, cracks,
scoring, and spalling.
• Thrust washers for wear.
• The fit of the side gears on the axle shafts.
• Differential case for cracks and scoring.
• Thrust sleeve for excessive wear. Do not replace
the thrust sleeve unless necessary. Inspect the
side gear bore for scoring. If scoring is present,
replace the entire differential.
• If any damage to the differential case is found, the
entire differential must be replaced.
• Replace parts as necessary.