Chevrolet 1988 Light Duty Truck Repair Manual page 199

SHIMS
Inspect
• Shims for cracks and chips. Damaged shims should
be replaced with an equally sized service shim.
ASSEMBLY OF THE REAR AXLE
PINION ASSEMBLY
DIFFERENTIAL CASE ASSEMBLY
-►*- Install or C onnect (F ig u re 1)
Lubricate all parts with rear axle lubricant.
New side gear thrust washers (27) to the side gears
(25).
2
Side gears (25) to the differential case.
.
• Place the side gears in place on the same side
as removed (figure 17).
3. Pinion gears (24) to the differential without the thrust
washers (26).
• Place the pinion gears onto the side gears so
that the holes in the pinion gears are 180
degrees apart.
• Rotate the pinion gears into place, and verify
that the pinion gears line up with the pinion
shaft holes.
4.
New pinion thrust washers (26).
• Rotate the pinion gears toward the differential
opening just enough to slide in the pinion
thrust washers.
5. Pinion shaft (28).
• Align the lock pin holes in the case and the
shaft.
6. Lock pin (29) (figure 18).
• Peen metal from the case over the lock pin.
C heck that the mating surfaces of the differential
case and the ring gear are clean and burr free.
Ring gear (20 to the differential case (22).
• T hre a d tw o s tu d s in to th e rin g g e a r on
opposite sides.
DANA REAR AXLES 4B5-7
Figure 18— Installing the Lock Pin
• Press the ring gear onto the case, and align
the holes in the case with the studs.
8. New ring gear bolts (23) (figure 19).
• Tighten the ring gear bolts a lte rn a te ly in
stages gradually pulling the ring gear onto the
differential case.
$
T ig h ten
• The new ring gear bolts in sequence to 150
N m (110 ft. lbs.). Refer to " S pecifications" for
bolt inform ation.
9. Master differential bearings D-117 (M iller Tools) to
the differential (figure 20).
• Refer to " Determ ining Total Shim Pack S ize" in this
section.
DETERMINING TO TAL DIFFERENTIAL SHIM
PACK SIZE
1. Assem ble the d ifferential case (22) to the axle
housing. The pinion must not be installed.
Figure 19— Installing the Ring Gear Bolts