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