Chevrolet 40 60 Series User manual

40-60 SERIES TRUCK
SUPPLEMENT
ST 334-72

1
1972
CHASSIS OVERHAUL MANUAL
SUPPLEMENT
SECTION INDEX
SECTION NAME
4REAR AXLE
DIFFERENTIAL CARRIER
covering
SERIES 40-60
CHEVROLET TRUCKS 5POWER BRAKE
CYLINDER
O R E W O R D 6M CARBURETORS
This manual includes procedures involved in disassembly and
assembly of major components peculiar to Series 40-60 Trucks,
and is a supplement to the 972 Passenger Car and Series 0-30
Truck Chassis Overhaul Manual. Information on maintenance and
adjustments, minor service operations, and removal and installa
tion of components is contained in the 972 Series 40-60 Truck
Chassis Service Manual.
The Section Index on this page enables the user to quickly
locate any desired section. At the beginning of each section
6Y DELCOTRON
containing more than one major subject is a Table of Contents,
which gives the page number on which each major subject begins.
An index is placed at the beginning of each major subject within
the section.
This manual should be kept in a handy place for ready
reference. If properly used, it will enable the technician to better
service the owners of Chevrolet built vehicles.
All information, illustrations and specifications contained in
7TRANSMISSION
AND CLUTCH
this literature are based on the latest product information avail
able at the time of publication approval. The right is reserved to
make changes at any time without notice. 9STEERING GEAR
AND POWER CYLINDER
CHEVROLET M O TO R D IVISIO N
General Motors Corporation
DETROIT, MICHIGAN
SPECIFICATIONS
© 972 General Motors Corporation Printed in U.S.A.

REAR AXLE DIFFERENTIAL CARRIER 4-1
SECTION 4
REAR AXLE DI ERENTIAL CARRIER
CONTENTS OF THIS SECTION
4-26
4-30
4-44
11.000 Through 17,000 lb. Capacity Single Spee .. 4-1
15.000 an 17,000 lb. Capacity Two Spee .............. 4-9
Differential Case an Drive Pinion (Eaton) 18,500
an
23.000 lb. Capacity Single Spee ................................ 4-20
Differential Case an Drive Pinion (Eaton) 18,500
an
23,000 lb. Capacity Two Spee .................................
Tan em Rear Axles an Power Divi er .................
Special Tools .................................................................
11,000 THROUGH 17,000 LB. CA ACITY SINGLE-S EED
(See Figures 1G, and 2G)
INDEX
Case an Drive Pinion ....................................................... ... 4-1
Removal ......................................................................... ... 4-1
Disassembly.................................................................... ... 4-1
Repairs .............................................................................. .... 4-4
Pinion Disassembly.......................................................... ... 4-4
Pinion Inspection .......................................................... ... 4-4
Pinion Reassembly .......................................................... ... 4-5
Differential Disassembly ............................................... .... 4-6
Differential Inspection ................................................... .... 4-6
Ring Gear Replacement ............................................... .... 4-6
Differential Bearing Replacement................................ .... 4-6
Differential Reassembly ............................................... .... 4-6
Reassembly ................................................................... ..... 4-7
Ring Gear an Pinion A justments ................................ .... 4-7
Checking Pinion Depth ............................................... .... 4-8
Ring Gear Thrust Ba A justment................................ .... 4-8
Installation .................................................................... .... 4-9
Case and Drive inion
Removal
1. Drain lubricant from ifferential, remove axle shaft as
outline in Truck Service Manual. See "Axle Shaft Re
moval".
2. Remove two trunnion bearing "U" bolts from the rear
yoke an split the rear universal joint.
NOTE: The bearings can be left on the trunnion and
held in place with tape.
3. Swing propeller shaft to’one si e an tie to the frame
si e rail.
4. Remove bolts an lock washers which retain the carrier
assembly to the axle housing. Support the ifferential
housing with a floor jack an roll it from un er truck.
Disassem bly
1. Mount carrier assembly in a bench vise or hol ing fix
ture.
2. On all axles except 13,500 lb., loosen ring gear thrust
pa locknut an remove thrust pa .
3. Remove ifferential a justing nut locks an bearing cap
bolts an lock washers.
4. Mark bearing caps an carrier for reassembly in same
position. Remove bearing caps an a justing nuts by
tapping on bosses of caps with a soft face hammer until
caps are free from owels.
CAUTION: Do not attempt to pry cap off as this may
damage machined face of cap.
5. Remove ifferential an ring gear assembly from the
carrier.
CAUTION: Exercise care that differential bearing
outer races are not dropped in removing assembly
from carrier.
6. Remove the bolts which attach the pinion bearing re
tainer to the carrier.
7. Remove the pinion an bearing assembly from the car
rier.
NOTE: It may be necessary to drive this unit from
carrier. Use brass drift against pilot end of pinion.
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-2 REAR AXLE DIFFERENTIAL CARRIER
. Universal Joint Yoke 8. Ring Gear Thrust Pad 4. Axle Shaft
2. Pinion Bearing Oil 9. Ring Gear 5. Differential Bearing
Seal and Retainer 0. Differential Spider 6. Differential Bearing
3. Oil Seal . Differential Pinion Adjusting Nut
4. Oil Seal Gasket (Spider) Gear 7. Adjusting Nut Lock
5. Front Pinion Bearing 2. Differential Side Gear 8. Differential
6. Drive Pinion 3. Differential Case-Left Case-Right Half
7. Rear Pinion Bearing Half
Fig. G-- ,000 lb. Capacity Axle-Cross Section
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

- \
REAR AXLE DIFFERENTIAL CARRIER 4-3
. Universal Joint Yoke 6. Drive Pinion . Differential Pinion 5. Differential Bearing
2. Pinion Bearing 7. Rear Pinion Bearing (Spider) Gear 6. Differential Bearing
Retainer 8. Ring Gear Thrust Pad 2. Differential Side Gear Adjusting Nut
3. Oil Seal and Screw 3. Differential Case 7. Adjusting Nut Lock
4. Shims 9. Ring Gear (Left Half) 8. Differential Case
5. Pinion Bearing Assembly 0. Differential Spider 4. Axle Shaft (Right Half)
Fig. 2G-- 3,500, 5,000 and 7,000 lb. Capacity Axle-Cross Section
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-4 REAR AXLE DIFFERENTIAL CARRIER
Fig. 3G— Pinion Rear Bearing Removal
(All Axles Except ,000 Lb.)
8. On all axles except the 11,000 lb., remove shims from
carrier making note of number an total thickness of
shims remove .
9. On all axles except the 11,000 lb., the pinion rear bear
ing outer race an roller assembly is presse into the
carrier. Remove assembly by riving it from its seat
using a soft rift or punch (fig. 3G).
Repairs
Pinion Disassembly
1. Clamp pinion rive flange in bench vise.
2. Remove cotter pin, nut an washer from en of pinion.
3. Remove rive flange an bearing retainer assembly
from pinion.
4. Drive oil seal from retainer. Discar seal as new parts
shoul be use at assembly.
5. On the 11,000 lb. axle, remove pinion rear bearing snap
ring an press bearing from pinion, using Tool J-1453
(fig. 4G).
Fig. 4G~Pinion Rear Bearing Removal ( ,000 Lb. Axle)
Fig. 5G--Pinion Rear Bearing Inner Race Removal ( 3,500.
5,000 and 7,000 Lb. Axles)
Fig. 6G-Drive Pinion Front Bearing Removal ( ,000 Lb. Axle)
6. On the 13,500, 15,000, an 17,000 lb. axles press inner
race of rear bearing from pinion, using Tools J-0358 an
J-1453 (fig. 5G).
7. On the 11,000 lb. axles, position rive pinion in an arbor
press so that the bearing is supporte by two pieces of
flat steel stock as shown in Figure 6G. Place flat stock
parallel to each other an against pinion so as to pick
up a large area of bearing outer race. Press pinion from
bearing making sure pinion is supp^'te to prevent
amage when remove from bearing
8. On the 13,500, 15,000 an 17,000 axles, press the pinion
front bearing assembly from the pinion as shown in
Figure 7G using appropriate tool as follows:
a. J-6171-five tooth pinion.
b. J-6203-six tooth pinion.
c. J-2225-seven tooth pinion.
Pinion Inspection
1. Wash all parts in cleaning solvent.
2. Inspect pinion for score , cracke , chippe or worn
teeth.
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

REAR AXLE DIFFERENTIAL CARRIER 4-5
Fig. 7G~Removal Drive Pinion Front Bearing (Typical) ( 3,500,
5,000 and 7,000)
3. Inspect splines on pinion shaft for excessive wear.
4. Inspect pinion bearing assemblies for roughness, efects
or excessive wear.
Pinion Reassembly
1. Pack the cavity between the pinion oil seal lips with a
lithium-base EP lubricant to provi e initial lubrication
an to ai in inserting pinion flange.
2. Press the oil seal into the retainer-position seal lips
towar the pinion bearing-using Tool J-22281 as
shown in Figure 8G.
3. On 13,500, 15,000 an 17,000 lb. axles, lubricate the
pinion rear bearing an carefully press it into carrier.
Then install the inner race on the 13,500, 15,000 an
17,000 lb. axle pinion shaft as shown in Figure 9G.
4. Install the 11,000 lb. axle pinion rear bearing assembly
on pinion shaft making sure that chamfere si e of
inner race seats against shoul er on pinion shaft. Then
install pinion bearing lock ring using Tool J-1364 as
shown in Figure 10G.
5. Install pinion front bearing as follows:
a. 11,000 lb. axles-Position the one-piece ouble row
Fig. 8G--Pinion Oil Seal Installation (Typical)
Fig. 0G~Pinion Rear Bearing Lock Ring Installation ( ,000
Lb. Axle)
ball bearing on pinion shaft, so that exten e por
tion of inner race is towar pinion hea . Then, using
a suitable length of 2 inch pipe, press bearing onto
shaft until it seats against the pinion hea .
CAUTION: When pressing bearing on pinion, exer
cise care to prevent damage to ground surface of
pilot.
b. 13,500, 15,000 an 17,000 lb. axles-Place one cone
an roller assembly on pinion shaft so that large en
of bearing is towar pinion then position outer race,
spacer an cone an roller assembly on pinion shaft.
Position pinion an bearing assembly in press as
shown in Figure 11G an seat bearing against pin
ion hea .
NOTE: The opposed tapered bearing assembly is
serviced as a unit and consists of one double outer
race, two inner race and roller assemblies and one
spacer. These parts should always be installed as a
group as the spacer is preselected to give proper
pinion bearing adjustment.
6. Sli e oil seal retainer on pinion shaft, then tap rive
flange onto pinion splines.
7. Clamp rive flange in a bench vise an install flange
Fig. 9G--Pinion Rear Bearing Inner Race Installation ( 3,500,
5,000 and 7,000 Lb. Axles)
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-6 REAR AXLE DIFFERENTIAL CARRIER
Fig. G--Pinion Front Bearing Installation ( 3,500, 5,000 and
7,000 Lb. Axles)
washer an nut. Torque nut to specifications an install
cotter pin without backing off on nut.
Differential Dissembly
1. Check ifferential case to make sure that the two halves
are marke so they may be reassemble in same relation
(fig. 12G).
2. Remove bolts hol ing case an cover together.
NOTE: Ring gear is mounted on the case.
3. Separate cover from case an remove ifferential si e
gears an thrust washers, pinion gears with thrust
washers an ifferential spi er.
Differential Inspection
1. Wash all parts thoroughly in cleaning solvent.
2. Inspect ring gear for chippe , score or worn teeth.
3. Check ra ial clearance between ifferential si e gears
an ifferential case, also fit of ifferential pinions on
spi er.
4. Inspect spi er arms for wear an istortion.
5. Inspect splines an teeth of ifferential si e gears an
pinions for chipping or excessive wear.
Fig. 2G--Differential Case Line-Up Marks
Fig. 3G--Differential Bearing Removal
6. Check thrust washers for wear an replace if even slight
wear is in icate .
7. Check ifferential si e bearings an cups for broken
races, iscoloration or roughness.
8. Inspect ifferential case for cracks or istortion.
Ring Gear Replacement
1. Remove ring gear from case by tapping the back of the
gear with a soft face hammer.
2. Inspect ring gear pilot case flange an back of ring gear
for irt or burrs.
3. Install two gui e pins (ma e from cap screws with
hea s cut off an en s slotte ) to new gear iametri
cally opposite each other.
4. Start gui e pins through case flange an tap ring gear
on case.
Differential Bearing Replacement
1. Install Tool J-8107 making sure puller legs are fitte
securely in notches in case an tighten retaining yoke
(fig. 13G).
2. Tighten puller screw to remove bearing.
3. Place new bearing on hub with thick si e of inner race
towar case an install bearing using appropriate tool
as shown in Figure 14G.
a. J-1488-11,000 lb. axle.
b. J-22300-13,000 lb. axle.
c. J-22301—15,000 an 17,000 lb. axles.
NOTE: The side bearing tool is counterbored and
has pilot to assure proper installation and seating of
bearing.
Differential Reassembly
1. Lubricate ifferential si e gears, pinions an thrust
washers.
2. Place ifferential pinions an thrust washers on spi er.
3. Assemble si e gears an pinions an thrust washers to
left half of ifferential case.
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

REAR AXLE DIFFERENTIAL CARRIER 4-7
Fig. 4G-Differential Bearing Installation
4. Assemble right half of case to left half being sure to line
up marks on the two halves.
5. Install ifferential-to-ring gear bolts an lock washers
an tighten evenly until ring gear is flush with case
flange.
6. Remove two gui e pins an install remaining two bolts.
Torque all bolts alternately an evenly to specifications.
Reassembly
To facilitate a justing of pinion epth in the ring gear,
there are five shims available for service use. They are .012",
.015", .018", .021" an .024".
NOTE: Pinion depth adjustment shims are not re
quired for the 1 1 ,0 0 0 lb. axle.
If the original ring gear an pinion are to be use it is
a visable to replace the same thickness of shims in the carrier
counter bore that were remove .
If a new ring gear an pinion are use , one .021" shim
shoul be use as a stan ar starting set up.
1. Place shim in bore in carrier or between carrier an
pinion oil seal retainer.
2. Place new pinion bearing retainer gasket on the retainer
an install pinion assembly in carrier.
NOTE: The pinion assembly should be pressed into
the carrier to prevent the possibility of damaging
the shims.
3. Install pinion bearing retainer bolts an lock washers
an torque bolts to specifications.
4. Lubricate ifferential bearing rollers with engine oil
an place outer races over them.
5. Install ifferential assembly in carrier an install a 
justing nuts.
Fig. 5G~Ring Gear and Pinion Adjustment
CAUTION: Carefully slide adjusting nuts alongside
the bearings so that threads on nuts fit into threads
in carrier.
6. Install ifferential bearing caps making sure the marks
on the caps line up with the marks on the carrier.
7. Install bearing cap bolts an lock washers an tighten
until lock washers just flatten out.
Ring Gear and Pinion Adjustment
1. With ifferential bearing cap bolts loosene just enough
to permit turning bearing a justing nuts with Tool J-
0972, remove all lash between ring gear an pinion (fig.
15G).
2. Back off left han a justing nut one to two notches to
a locking position.
3. Tighten right han a justing nut firmly to force iffer
ential in soli contact with left han a justing nut.
4. Back off right han a justing nut until free of bearing;
then retighten snugly against bearing.
5. Tighten right han nut from one to two a itional
notches to a locking position.
NOTE: This method of adjustment provides for
proper preload of bearings.
6. Mount a ial in icator on the carrier an check the
backlash between ring gear an pinion (fig. 16G). Back
lash shoul be from .003" to .012" (.005" to .008"
preferre ).
NOTE: If backlash is more than .0 2" loosen the
right hand adjusting nut one notch and tighten left
hand adjusting nut one notch. If backlash is less
than .003" loosen the left hand adjusting nut one
notch and tighten right hand nut one notch.
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-8 REAR AXLE DIFFERENTIAL CARRIER
Fig. 6G~Checking Ring Gear and Pinion Backlash
Fig. 7G-Gear Tooth Nomenclature
7. Tighten bearing cap bolts to specifications.
8. Install si e bearing a justing nut locks an torque to
specifications.
Chec ing Pinion Depth
1. Coat the ring gear teeth lightly an evenly with a mix
ture of pow ere re lea an oil of a suitable consist
ency to pro uce a contact pattern. Then turn the pinion
shaft several revolutions in both irections.
2. Examine the pattern on the ring gear teeth. If the pinion
epth is correct, the tooth pattern will be centere on
the pitch line Fig. 17G an towar the toe of the ring
gear (fig. 18G).
3. If the pattern is below the pitch line on the ring gear
teeth, the pinion is too eep an it will be necessary to
remove the pinion assembly an increase the shim
thickness between the pinion bearing an the carrier.
4. If the pattern is above the pitch line on the ring gear
teeth, the pinion is too shallow an it will be necessary
to remove the pinion assembly an ecrease the shim
thickness between the pinion bearing an the carrier.
5. Changing the pinion epth will make some change in
the backlash; therefore, it will be necessary to rea just
the backlash.
Ring Gear Thrust Pad Adjustment
( 11,000, 15,000 an 17,000 Lb. Axles)
1. Inspect bronze tip of thrust pa an if worn install a
new one.
2. Install thrust pa an tighten screw until bronze tip
engages back face of ring gear while rotating gear.
3. Back off screw one-twelfth (1/12) turn an tighten
locknut to specifications (fig. 19G).
FACE CONTACT FLANK CONTACT
TOE CONTACT CORRECT
TOOTH
CONTACT
HEEL CONTACT
Fig. 8G--Gear Tooth Contact Patterns
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

REAR AXLE DIFFERENTIAL CARRIER 4-9
| LOCK NUT
Fadjusting
SCREW
Fig. 9G~Ring Gear Thrust Pad Adjustment
NOTE: Make sure screw does not turn during lock
ing process. This adjustment provides .005" to .007"
clearance between thrust pad and ring gear face.
Installation
1. Clean out axle housing an cover an place new gasket
over axle housing.
2. Assemble ifferential carrier to axle housing, install
lockwashers an bolts an tighten securely.
3. Replace axle housing inspection cover, if remove , us
ing new gasket.
NOTE: This propeller shaft to pinion flange fastener
is an important attaching part in that it could affect
the performance of vital components and systems,
and/or could result in major repair expense. It must
be replaced with one of the same part number or
with an equivalent part if replacement becomes
necessary. Do not use a replacement part of lesser
quality or substitute design. Torque values must be
used as specified during reassembly to assure
proper retention of this part.
4. Assemble rear universal joint.
5. Install axle shafts as outline in applicable axle installa
tion proce ure in Service Manual.
6. Fill axle with lubricant to a level even with bottom of
filler hole. See Section 0 Service Manual for proper
lubricant.
1 5,000 AND 17,000 LB. CA ACITY TWO-S EED
INDEX
Differential Carrier Assembly .................................... 4 .9
Removal....................................................................... 4 .9
Disassembly ................................................................ 4 4 2
Repairs......................................................................... 4 4 3
Drive Pinion an Bearing Retainer .................. 443
Disassembly ....................................................... 4 .1 3
Inspection............................................................ 4-14
Reassembly.......................................................... 4-14
Differential an Planet ........................................ 4-15
Disassembly ....................................................... .... 4-15
Inspection............................................................ .... 4-16
Reassembly.......................................................... .... 4-17
Reassembly ............................................................ .... 4-17
Ring Gear an Pinion A justment ................ .... 4-18
Checking Pinion Depth.................................... .... 4-19
Shifting Yoke, Sleeve an Shaft Installation 4-19
Installation.............................................................. .... 4-19
DIFFERENTIAL CARRIER ASSEMBLY
Removal
1. Loosen the lower carrier-to housing attaching cap
screws an rain lub' icant from housing.
2. Remove axle shafts an electric or vacuum lines as
outline in Truck Service Manual.
3. Remove propeller shaft from pinion flange. Tape bear
ing caps to keep them in place. Swing the propeller shaft
to one si e an tie it to the frame si e rail.
4. Remove all ifferential carrier-to-axle housing cap
screws an lock washers exept two near top of carrier.
Loosen the two cap screws at the top, but leave installe
to prevent carrier from falling.
5. Tap along the outer perimeter of the carrier with a
soft-face hammer to break bon between carrier an
housing.
6. Support carrier with a roller jack, then remove the
remaining cap screws an lock washers. Work the as
sembly forwar until it clears the housing. A small,
roun pry bar or a long rift may be inserte in one of
the upper holes to keep carrier aligne with housing.
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-10 REAR AXLE DIFFERENTIAL CARRIER
24 23 25. Magnetic Chip
. Pinion Flange 0. Pinion Rear Bearing 8. Thrust Washers Collector
2. Dust Deflector . Differential and 9. Differential and 26. Planet Gears (4)
3. Pinion Oil Seal Planet Support Planet Support Case 27. Differential and
4. Pinion Front Bearing 2. Differential Bearing Cover Planet Support Case
5. Pinion Adjusting (Right) 20. Axle Housing Cover 28. Shift Yoke
Shim 3. Axle Shaft (Welded) 29. Shift Sleeve
6. Pinion Bearing 4. Axle Housing 2 . Differential Pinion 30. Anchor Bolt Lock
Preload Spacer 5. Differential Bearing 22. Filler Plug 3 . Anchor
7. Pinion Intermediate Adjusting Nut (Right) 23. Differential Pinion 32. Sun Gear
Bearing 6. Oil Baffle Shaft 33. Ring Gear
8. Pinion 7. Adjusting Nut Lock 24. Differential Side Gear 34. Pinion and Bearing
9. Differential Carrier (Right) (Left) Retainer
Fig. J-Two-Speed Axle Cross Section
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

CHEVROLET OVERHAUL MANUAL SUPPLEMENT
. Pinion Retaining Nut 8. Pinion Intermediate 6. Differential Bearing 2 . Differential Baring 26. Differential Pinion 3 .
and Washer Bearing Adjusting Nut and Oil Cap (Left) Shaft 32.
2. Pinion Flange and 9. Pinion Baffle 22 Differential and 27. Differential Pinion
Dust Deflector 0. Pinion Rear Bearing 7. Differential Bearing Planet Support Case and Thrust Washer 33.
3. Pinion Oil Seal . Shift Unit (Vacuum) (Right) Cover (4)
4. Pinion Front Bearing 2. Shift Unit Mounting 8. Ring Gear 23. Thrust Washer 28. Differential Side Gear 34.
5. Pinion and Bearing Bracket 9. Differential Bearing 24. Differential and (2)
Retainer 3. Shifter Yoke Lever Cap (Right) Planet Support Cover 29. Differential and 35.
6. Pinion Adjusting 4. Differential Carrier 20. Adjusting Nut Lock 25. Adjusting Nut Lock Planet Support 36.
Shim 5. Oil Trough (Right) (Left) 30. Planet Gears (4) 37.
7. Pinion Bearing
Preload Spacer 38.
Fig. 2J~Exploded View of Carrier
Sun Gear
Differential and Plane
Support Case
Differential Bearing
(Left)
Differential Bearing
Adjusting Nut (Left)
Shift Sleeve
Shift Yoke
Shift Anchor
Anchor Bolt Lock
REAR AXLE DIFFERENTIAL CARRIER 4-

4-12 REAR AXLE DIFFERENTIAL CARRIER
Fig. 3J--Removing Drive Pinion Nut (Typical)
Disassem bly
(Refer to Figure 2J for Carrier Components)
1. Place ifferential carrier assembly in a suitable repair
stan or in a large vise with pa e jasws an clamp
securely to prevent assembly from falling.
2. Using Tool J-3453 to hol flange, remove rive pinion
nut an washer (fig. 3J). Discar nut an use a new nut
for reassembly.
3. Remove flange from pinion by tapping on flange with
a brass rift an hammer.
4. Remove cap screws securing pinion bearing retainer to
carrier. Rap retainer sharply with a soft-face hammer
to loosen retainer from carriea If require a blunt chisel
may be use between the carrier an retainer to sepa
rate them.
5. With raw retainer an pinion from carrier an remove
shim(s) from between carrier an retainer. Save shim(s)
to facilitate a justment uring reassembly.
6. Remove the three bolts an lock washers retaining
shifter assembly to the carrier an remove the shifter
assembly.
7. Ben tang on bolt lock own an remove bolt an bolt
lock from shift yoke anchor, then remove anchor from
carrier.
8. Drive out shifter yoke shaft, using rift an hammer as
shown in Figure 4J.
9. Sli e the shifter yoke an sleeve to the left, removing
the sleeve an shifter yoke from the en of the sun gear
(fig. 5J).
10. Remove ifferential bearing a justing nut lock from
each nut an remove locks from both si es.
Fig. 4J-Removing Shifter Yoke Shaft
11. Remove the two retaining bolts an with raw oil
trough from the carrier (fig. 6J).
12. Remove bearing caps an a justing nuts by tapping on
bosses of caps until free from owels (fig. 7J). Remove
the ifferential an planet assembly from the housing.
Fig. 5J--Removing Shifter Yoke and Sleeve
Repairs
Drive Pinion and Bearing Retainer Disassembly
1. Pry pinion oil seal from the retainer using care not to
amage machine surfaces.
2. Position retainer an pinion assembly in an arbor press
with retainer resting on be of arbor. Press pinion
ownwar an out of retainer (fig. 8J). Remove pinion
front bearing inner race from the retainer an remove
bearing spacer from pinion- iscar spacer.
3. Using 1/2 inch bar stock, cut to a suitable length an
positione in the provi e notches, press pinion front
an interme iate bearing cups from the retainer (fig.
9J).
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

REAR AXLE DIFFERENTIAL CARRIER 4-13
Fig. 6J~Removing Oil Trough
Fig. 7J-Removing Bearing Caps
4. Select appropriate tool as require an remove pinion
interme iate inner bearing from the rive pinion as
follows.
a. 6-tooth pinion—position Tool J-6203 over hea of
pinion so that it contacts inner race of bearing, an
press pinion from bearing (fig. 10J).
b. 7-tooth pinion—position the two halves of J-22307
over the pinion bearing so that the lip of tool picks
up the bearing rollers (fig. 11J). Tighten the two
halves with provi e bolts until bearing is fully
seate in tool. Press pinion from bearing (fig. 12J).
5. Remove the pinion rear bearing from the carrier by
tapping on the outer race with a brass rift to unseat the
bearing (fig. 13J).
Inspection
1. Wash all metal parts thoroughly in cleaning sol
vent an ry with air.
Fig. 8J~Removing Pinion from Retainer
CAUTION: Do not spin bearings while drying with
air hose.
2. Inspect the rive pinion for chippe , cracke or exces
sively worn teeth an inspect the splines for wear. In
spect the bearings for worn or pitte rollers or inner
races. Inspect the pinion flange for worn splines.
3. Inspect bearing retainer for cracks, an any imperfec
tions such as corrosion, pits an grooves in the oil seal
area.
4. Replace efective parts as require .
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-14 REAR AXLE DIFFERENTIAL CARRIER
Fig. J—InstaKing J-22307 to Pinion Bearing
Fig. 2J--Removing Pinion Intermediate Bearing Using
J-22307
Fig. 3J--Removing Pinion Rear Bearing from Carrier
NOTE: The pinion and ring gear are serviced in
matched sets only. Therefore, if replacement is re
quired both new components must be installed.
Reassembly
1. Position pinion front bearing outer race in the bearing
retainer with the thick e ge of race towar internal
shoul er in retainer. Using Tool J-22306 an Driver
Han le J-8092 press race into retainer until it is firmly
seate against shoul er.
2. Position pinion interme iate bearing outer race in re
tainer as escribe in Step 1; then, using Tool J-22377
an Driver Han le J- 8092, install race as above until
it seats firmly against shoul er (fig. 14J).
3. Install pinion interme iate bearing inner race on pinion
with thick en of race towar pinion hea , using a
suitable length of 2 inch I.D. pipe to press against inner
race (fig. 15J).
4. Place pinion bearing spacer over pinion an against
bearing, then position pinion in retainer an install
front bearing inner race over pinion-thin e ge of inner
race towar bearing spacer.
5. Press front bearing on pinion so that inner race contacts
bearing spacer. A suitable length of 2 inch I.D. pipe
may be use to install the bearing (fig. 16J).
CAUTION: The pilot end of the pinion serves as an
inner race for the pinion rear bearing, exercise care
so as not to damage this machined surface.
6. Pack the cavity between the seal lips with a lithium-base
extreme pressure lubricant an install the pinion oil seal
in the retainer bore, using Tool J-22283 (fig. 17J). Press
the seal into the bore until it bottoms against internal
shoul er.
Fig. 0J--Removing Pinion Intermediate Bearing Using J-6203
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

REAR AXLE DIFFERENTIAL CARRIER 4-15
Fig. 4J—Installing Pinion Intermediate Bearing Outer Race
Fig. 5J—Installing Pinion Intermediate Bearing Inner Race
7. Position pinion rear bearing into carrier bore an install
bearing so that it seats against stop, using Tool J-22303
an Driver Han le J-8092 (fig. 18J).
Fig. 7J--Installing Pinion Oil Seal
Differential and lanet
Disassembly
1. Mark the ring gear an ifferential an planet support
case an case cover for alignment by scribing or making
lines on case, cover an gear (fig. 19J).
2. Remove the retaining bolts an lock washers retaining
ring gear to planet support case an cover assembly an
remove cover.
3. Mark or tag all gears so that they may be reassemble
in the same relative position; then remove the sun gear
an planet gears.
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-16 REAR AXLE DIFFERENTIAL CARRIER
Fig. 8J—Installing Pinion Rear Bearing
Fig. 9J~Alignment Marks on Ring Gear, Case and Cover
4. Lift the ifferential an planet support assembly from
the support case.
5. Remove the retaining bolts an lock washers from the
planet support an cover, then separate the two parts
(fig. 2 0 ).
6. Mark or tag all parts for reassembly in same relative
position, then remove the spi er, pinion gears an
thrust washers.
7. Remove the right an left si e gears an thrust washers
from each si e of the housing.
8. Remove the ifferential bearings from the ifferential
planet support case an case cover by inserting a suita
ble size rift through the cast holes in the case an
cover. Tap alternately through the holes from si e to
si e of bearing to prevent race from bin ing on hub
(Fig. 21J).
Fig. 2 J~Removing Differential Bearings Using Brass Drift
Inspection
1. Clean all parts thoroughly in cleaning solvent.
2. Inspect the ring gear, planet gears, ifferential pinion
gears, an sun gear for amage teeth or excessive
wear. Inspect the thrust washers for excessive wear.
Inspect the spi er for wear or score pinion bearing
area. Inspect the ifferential si e gears an thrust wash
ers for amage teeth or excessive wear.
3. Replace all amage or excessively worn parts inclu 
ing mating parts where necessary.
Fig. 20J-Separating Support Case and Cover
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

REAR AXLE DIFFERENTIAL CARRIER 4-17
Fig. 22J—InstaIIing Differential Bearings
Fig. 23 J--ln sta lling Ring Gear U sing Im provised G uide Pins
Reassembly
1. Replace ifferential bearings using Tool J-22294 for the
left bearing an Tool J-22295 for the right bearing (fig.
22J). Both tools have a pilot to permit proper alignment
of the bearing with the hub. Install both bearings until
they are firmly seate on the case or cover as applicable.
2. Lubricate the thrust washers, si e gear, spi er an if
ferential pinion gears. Assemble the parts in the iffer
ential an planet support, using reference marks ma e
at isassembly to properly align parts.
NOTE: The side gear with the longest hub should be
positioned in the support cover. Make sure side gear
thrust washers are in place before installation.
3. Align an install cover-torque retaining bolts to
specifications.
4. Install the planet gears on the support journals, then
position the sun gear in the planet gears.
5. Install ring gear to support cover, using alignment
marks previously scribe . Improvise gui e pins ma e
from ring gear retaining bolts with hea s cut off an
slotte may be use to gui e cover onto ring gear (fig.
23J).
6. Support the ifferential an planet support cover an
ring gear with ring gear teeth on two blocks of woo ;
then the assemble palnet an ifferential assembly into
cover. Make sure thrust washer is in position at bottom
of case.
7. Align an install the ifferential an planet support
case, using the alignment marks previously scribe in
isassembly proce ures.
8. Install case-to-ring gear bolts an lock washers in holes
that o not have gui e pins installe , then remove gui e
pins an install remaining bolts. Tighten bolts in a
cross-wise pattern to raw case, cover an ring gear
evenly together. Torque all bolts to specifications
Installation
1. Position the ifferential bearing outer races on the bear
ing, then using a suitable lift, position the ifferential
into the carrier.
2. Install the ifferential a justing nuts in each si e of the
carrier.
3. Position the ifferential bearing caps in the carrier mak
ing sure that the a justing nuts properly engage the
threa s in the caps (fig. 24J). Bearing caps will seat
flush with carrier an a justing nuts will turn freely if
caps are properly installe . Tap caps lightly with a
soft-face hammer to seat, but o not attempt to force
caps on nuts.
4. Tighten cap bolts evenly until the a justing nuts turn
freely in the threa s.
Fig. 24J—Installing Differential Bearing Caps
CHEVROLET OVERHAUL MANUAL SUPPLEMENT

4-18 REAR AXLE DIFFERENTIAL CARRIER
Fig. 25J—Installing Pinion Bearing Shim
5. Using the original shim pack remove in isassembly
proce ures, install shim pack on the carrier, aligning
holes in shim(s) with holes in carrier (fig. 25J).
6. Carefully gui e the pinion an bearing retainer assem
bly into the carrier bore. Making sure rear of pinion is
properly seate in pinion rear bearing.
7. Install bearing retainer-to-carrier bolts an lock wash
ers an torque bolts to specifications.
8. Install pinion flange to pinion, making sure splines are
properly engage , then tap gently on flange with soft-
face hammer until sufficient clearance for washer an
nut installation is obtaine .
9. Install washer an self-locking nut to pinion, an using
hol ing Tool J-3453 to hol flange, tighten pinion nut
to seat flange an to preloa pinion bearings.
NOTE: To properly preload the pinion bearings it
may be necessary to apply torque up to 500 ft. lbs.
at the pinon nut.
10. Tighten nut until flange, bearings an spacer are all
Fig. 27J~Tightening Differential Right Adjusting Nut Using J-
0972
firmly seate then measure torque require to rotate
pinion.
11. Continue tightening in small increments an measure
until the torque require to rotate pinion is 25-35 in. lbs.
for new pinion bearings or 5-15 in. lbs. when use bear
ings are reinstalle (fig. 26J).
Ring Gear and Pinion Adjustment
1. Loosen right ifferential a justing nut an tighten left
a justing nut. Use Tool J-0972 on the right si e (fig.
27J) an a rift an hammer on the left si e (fig. 28J).
2. Tighten left a justing nut until the ring gear contacts
pinion an zero lash is obtaine ; however, o not force
gears into contact so as to bin them.
3. Back off left a justing nut approximately two notches
to a point where nut lock an nut are aligne . Install
nut lock an torque to specifications.
4. Tighten right a justing nut firmly to force the ifferen
tial an planet assembly into soli contact with left
a justing nut. Loosen right a justing nut until it is free
Fig. 28J-Tightening Differential Left Adjusting Nut Using Drift
CHEVROLET OVERHAUL MANUAL SUPPLEMENT
Fig. 26J-Measuring Pinion Rotating Torque