Assembly Of The Rear Axle - GMC 1990 Light Truck Repair Manual

SHIMS
I P 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 Connect (Figure 1)
Lubricate all parts with rear axle lubricant.
New side gear thrust washers (27) to the side gears
(25).
Side gears (25) to the differential case.
2
.
• 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.
Lock pin (29) (figure 18).
6.
• 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.
Ring gear (20 to the differential case (22).
• Thread two studs into the ring gear 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 alternately in
stages gradually pulling the ring gear onto the
differential case.
• The new ring gear bolts in sequence to 150
N m (110 ft. lbs.). Refer to " Specifications" for
bolt information.
9. Master differential bearings D-117 (Miller Tools) to
the differential (figure
• Refer to " Determining Total Shim Pack Size" in this
section.
DETERMINING TOTAL DIFFERENTIAL SHIM
PACK SIZE
1. Assemble the differential case (22) to the axle
housing. The pinion must not be installed.
Figure 19—Installing the Ring Gear Bolts
20
).