Assembly Of Axle; Differential Case Assembly - Chevrolet 1988 Light Duty Truck Repair Manual

4C2-8 9 /4-INCH RING GEAR FRONT AXLE
3
Im p o rtan t
Lubricate all seal lips, bearings, gears, and bearing
surfaces with axle lubricant prior to assembly.

DIFFERENTIAL CASE ASSEMBLY

-►+ Install or C o n n e c t (F ig u re 1)
Tool Required:
D-160, Axle Shaft Seal Installer (Miller)
• Lubricate all parts with front axle lubricant.
1. Axle shaft seals, using D-160 (figure 17).
2. New side gear thrust washer (27) to the side gears
(25).
3. Side gears (25) to the differential case.
• Place the side gears in place on the same side
as removed (figure 18).

ASSEMBLY OF AXLE

4. Pinion gears (24) to the differential w ithout the thrust
5. New pinion thrust washers (26).
6. Pinion shaft (28).
8. Ring gear (2) to the differential case (22).
10
Figure 19— Installing the Lock Pin
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.
• Rotate the pinion gears toward the differential
opening just enough to slide in the pinion
thrust washers.
• Align the lock pin holes in the case and the
shaft.
7. Lock pin (29) (figure 19).
• Peen metal from the case over the lock pin.
• Check that the mating surfaces of the differential
case and the ring gear are clean and burr free.
• T h re a d tw o s tu d s in to th e ring g e a r on
opposite sides.
• Press the ring gear onto the case, and align
the holes in the case with the studs.
9. New ring gear bolts (23) (figure 20).
Im p o rtan t
Always use new bolts at assembly.
Always use the correct service bolts. Do not
attem pt to use a substitute bolt.
Tighten the ring g ear bolts a lte rn a te ly in
stages gradually pulling the ring gear onto the
differential case.
T ig h ten
• The ring gear bolts in sequence to 142-156
N m (105 - 115 ft. lbs.).
Master differential bearings D-117 to the differential
.
(figure 21).