Assembly Of Axle; Differential Case Assembly - GMC 1989 Light Duty Truck Repair Manual

4C2-8 93/4-INCH RING GEAR FRONT AXLE
Im portant
Lubricate all seal lips, bearings, gears, and bearing
surfaces with axle lubricant prior to assembly.

DIFFERENTIAL CASE ASSEMBLY

-► <- Install or C onnect (Figure 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

Figure 19— In sta lling th e L ock Pin
4. 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.
5. New pinion thrust washers (26).
• Rotate the pinion gears toward the differential
opening just enough to slide in the pinion
thrust washers.
6. Pinion shaft (28).
• 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.
8 Ring gear (2) to the differential case (22).
.
• T hre ad two stu ds into the rin g g ea 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 portant
Always use new bolts at assembly.
Always use the correct service bolts. Do not
attempt to use a substitute bolt.
Tighten the ring gear bolts alternately in
stages gradually pulling the ring gear onto the
differential case.
T ighten
• The ring gear bolts in sequence to 142-156
N-m (105 - 115 ft. lbs.).
10. Master differential bearings D-117 to the differential
(figure 21).