Drive Axle Assembly; Outer Deflector Ring Replacement; Outer Joint Seal Replacement; Outer Joint Assembly Replacement - Chevrolet 1991 Light Duty Truck Repair Manual

4C4-20 8 1/4 AND 9 1/4-INCN RING GEAR
OUTER DEFLECTOR RING
REPLACEMENT
0
Remove o r Disconnect (Figures 40, 41 and 42)
• Clamp the axle shaft (12) in a vise.
• Use soft metal or wood to protect the shaft.
1. Deflector ring (19) from C/V outer race (18) with a
brass drift and a hammer as shown and discard
(figure 41).
|+ * | Install or Connect
• Position and square up the deflector ring (19)
at the press diameter of C/V outer race (18).
• Using a 3" pipe coupling (K10/20) or 4" pipe
coupling (K3), M24 x 2.0 nut and fabricated
sheet metal sleeve as shown in figure 43, tight­
en nut until deflector (19) bottoms against
shoulder of C/V outer race (18).
OUTER JOINT SEAL
REPLACEMENT
I * * ) Remove or D isconnect (Figures 40 and 43
through 46)
Tools Required:
J 8059 Snap Ring Pliers
J 35910 Seal Clamp Tool
J 36652 Swage Clamp Tool
1. Large swage ring (9) from the C/V joint, using a
chisel and discard.
m Im portant
• Do not cut through the seal (13) and damage
the sealing surface of C/V outer housing (18)
with the chisel.
2. Small seal-retaining clamp (11) on axle shaft with
a side cutter, and discard.
• Separate the joint seal (13) from the C/V joint race
(18) at large diameter and slide the seal away from
joint along the axle shaft (12).
• Wipe excess grease from face of C/V inner race
(16).
• Spread the ears on the race retaining ring (14) with
J 8059 as shown and remove the C/V joint assem­
bly from the axle shaft (12).
3. Seal (13) from the axle shaft (12).
• Disassemble the joint and flush grease prior to
installing the new seal. Refer to "Outer Joint
Assembly Replacement."
[»4] Install or Connect
1. Small seal-retaining clamp (11) on the neck of the
new seal (13). Do not crimp.
• Slide the seal (13) onto the axle shaft (12) and
position the neck of the seal in the seal groove on
the axle shaft.

DRIVE AXLE ASSEMBLY

• Crimp the self retaining clamp (11) with J 35910 to
136 N-m (100 ft. lbs.) (figure 45).
• Place approximately half of the grease provided
inside the seal (13) and repack the C/V with the
remaining grease.
2. Swage ring (9).
• Pinch by hand slightly to distort into an oval
shape and slide onto large diameter of the seal
(13).
• Push C/V joint onto axle shaft (12) until retain­
ing ring (14) is seated in groove on axle shaft.
• Slide large diameter of the seal (13) with the
large swage ring (9) in place over the outside
of the C/V joint race (18) and locate the seal lip
in the housing groove.
| V | Im portant
• The seal (13) must not be dimpled, stretched or
out of shape in any way. If the seal is not
shaped correctly, carefully insert a thin flat
blunt tool (no sharp edges)
seal opening and the outer race (18) at maxi­
mum clearance of oval ring (9) to release the
air. Shape the seal by hand and remove the
tool.
• Refer to the chart in figure 46 and select the
correct size swage clamp tool J 36652.
• Mount the proper size swage clamp tool in the
vise and proceed as follows:
— Position the outboard
in the tool.
— Place the top half of the tool on the lower half
of the tool and check for proper alignment (fig­
ure 46).
— Insert the bolts and tighten by hand until snug.
j 9 | im portant
• Make sure the seal (13), housing (18) and
swage ring (9) all remain in alignment (fig­
ure 46).
— Continue to tighten each bolt 180'at a time
alternately until both sides are bottomed.
• Remove the axle assembly from the tool.
OUTER JOINT ASSEMBLY
REPLACEMENT
Disassem ble (Figures 40, and 47 through 49)
• Perform steps 1 through 3 in "Outer Joint Seal
Replacement" in this section.
• Use a brass drift and a hammer to gently tap on
the C/V joint cage (17) until it is tilted enough to
remove the first chrome alloy ball (15) (see figure
47).
• Tilt the cage (17) in opposite direction to remove
opposing ball (15).
• Repeat this process until all six balls (15) are
removed.
between the large
end of the axle assembly