Chevrolet Chevelle 1977 Repair Manual page 117

2. Inspect clutch discs and plates for w ear, cracked, or
disto rted co n d itio n .
section.
3. Inspect side gear rings, side gears, and differential
cases for worn, cracked, or distorted condition that
w ould rend er these p arts unfit for fu rth e r services.
Assembly
D u rin g assem bly operations, all p arts should be kept
clean and free o f d irt or o ther fo reig n m aterial. As each
p a rt is assem bled in its p ro p e r position, it is necessary
th at it be lightly coated with the correct lubricant.
1. Place tab bed Belleville friction plate (4) in flanged
differential case, being
convex (bulged) side is tow ard the side gear. See
Figure 17D.
2. A ssem ble rem ain in g plates and discs to splines of
side gear ring, being sure they are assem bled in the
sam e o rder o f rem oval. T he convex (bulged) side o f
the Belleville friction disc (5) should be tow ard the
side gear and it should nest into the Belleville
friction plate (4).
3. Place assem bled side gear rin g w ith plates and discs
in flanged h a lf o f differential case.
4. Install side gear and cross sh afts w ith pinions.
5. In the order listed install the following: (1) side
gear, (2) side gear ring, (3) flat plate w ith tabs, (4)
flat disc w ith teeth, (5) flat plate w ith tabs, (6)
Belleville disc w ith convex (bulged) side up, or
tow ard side gear, (7) Belleville plate, w ith convex
(bulged) side up, or side tow ard gear.
6. Position p lain h a lf
previously assem bled p a rts w ith scribe m arkings on
both halves o f case in align m ent.
7. Install differential case bolts, but do not tighten at
this time.
REAR AXLE DIFFERENTIAL
R e fe r to "S p ec ific a tio n s"
extrem ely careful that
o f differential case over
8. Before tightening bolts, use axle shafts and align
splines o f the side gear and side g ear ring, on each
side. T ighten bolts evenly and alternately. Rem ove
axle shafts.
9. Observe if Power-Lok
assem bled properly. Each p in io n cross sh aft can be
tight on its ram p or if there is clearance it should
be only a few thousandths, and it should be equal
at all four cross sh aft ends.
Testing Procedure
T he Power-Lok can be effectively tested fo r correct
o p eratio n by placing one re a r w heel on good dry
p avem ent and the other on ice, snow, m ud, gravel,
grease, etc.
It can easily be d eterm ined w h eth e r or not the n o n ­
slipping wheel is p ro viding pulling pow er. T he procedure
should then be rep eated w ith the opposite wheels on the
dry and slippery surfaces.
The above testing procedure is a rough test th at can be
m ade by the ow ner o f the vehicle. However, if it is
suspected th at the unit is not o p e ra tin g properly, it can
be checked by the follow ing procedure.
Be sure the transm ission is in n eu tral. R aise one wheel
off the floor and place a block in the fro n t and re a r o f
the opposite wheel. Rem ove the hub cap and install a
special tool across two w heel studs. A pply a torque
w rench to special tool. D isreg ard breakaw ay torque and
observe only the torque req u ired to continously tu rn the
wheel sm oothly.
If the torque read in g is less th a n 40 foot-pounds or m ore
than 200 ft. lb., the unit should be disassem bled and the
necessary repairs m ade.
4B-45
com ponents have been