Join Date: 04-14-08
Location: South Lyon 48178
here's every step of tear down and re assy
Fig. 1 Exploded View Of Rear Differential.
Mount differential carrier in holding fixture tool No. J-34162-A, or equivalent, using differential housing adapter tool No. J-37769, or equivalent.
Mount differential carrier and holding tool in a suitable vise.
Scribe alignment marks in differential side bearing caps for assembling reference.
Remove side bearing lock plate and caps.
Remove side bearing adjusters and outer bearing races.
Remove rear wheel speed sensor.
Remove 10 ring gear assembly attaching bolts.
Separate differential left case with rear wheel anti-lock brake exciter ring from right case.
Remove exciter ring from left case using a suitable copper hammer. Tap evenly along the outer edge of exciter ring .
Turn differential carrier in fixture 90°.
Fig. 11 Universal Joint Flange Removal.
Using pinion flange holder J-8614-01, or equivalent, remove universal joint flange nut, Fig. 11 .
Remove universal joint flange and pinion shaft.
Using oil seal remover tool No. J-26941 and slide hammer tool No. J-23907, or equivalents, remove pinion shaft oil seal.
Remove outer pinion bearing from differential case.
Remove outer and inner pinion bearing races.
Fig. 12 Side Bearing Removal.
Using side bearing puller tool No. J-22888-D and side bearing remover pilot tool No. J-8107-4, or equivalents, remove differential side bearings, Fig. 12 .
Using an arbor punch and a hammer, remove shaft spring pins.
Remove differential side gears, selective shims, pinion gears, thrust washers and cross shafts.
Fig. 13 Inner Bearing Removal.
Using a suitable press and inner pinion bearing cone remover tool No. J-22912-01, or equivalent, remove collapsible spacer and inner pinion bearing, Fig. 13 . Discard collapsible spacer.
Ring gear and pinion must be replaced as a set. Taper roller bearings and races must be replaced as a set .
Using exciter ring installer tool No. J-38891, differential side bearing remover tool No. J-8107-4 and a suitable press or equivalents, install anti-lock brake exciter ring to differential left case as follows:
Fig. 14 Rear Wheel Anti-Lock Brake Exciter Ring Installation.
Install rear wheel anti-lock brake exciter ring using exciter ring installer tool No. J-38891, or equivalent, a differential side bearing installer tool No. J-8107-04, or equivalent and a press, Fig. 14. Pressure exerted on exciter ring should not exceed 1102 lbs. If more than 1102 lbs. of pressure is needed for press fitting, left case and exciter ring are probably not evenly aligned. Remove from press and repeat procedure .
Install rear speed sensor and torque bolt to 17 ft. lbs.
Install differential pinion gears, thrust washers, cross shafts and right side gear with selective shim in differential case.
Fig. 15 Right Side Gear Endplay Measurement.
Measure differential right side gear endplay using a suitable dial indicator, Fig. 15 . If end play is not .005-0.014 inch, select shim to obtain correct end play.
Install cross shaft spring pins into differential case until pins are flush with differential case surface.
Install left differential side gear, selective shim and ring gear into case.
Fig. 7 Bearing Preload Adjustment.
Measure differential left-side gear endplay using a suitable dial indicator and universal endplay measuring tool No. J-35138, or equivalent, Fig. 7 . If end play is not 0.005-0.014 inch, select shim to obtain correct end play.
Coat ring gear bolts with sealant part No. 1052624, or equivalent, then install bolts and torque to 63 ft. lbs.
Install differential right side bearing, using bearing cone installer tool No. J-24433, driver handle tool No. J-8092, or equivalents and a suitable press.
Install differential left side bearing, using bearing cone installer tool No. J-37758, driver handle tool No. J-8092, or equivalents and a suitable press.
Install bearing plug tool No. J-8107-4, or equivalent, on lower bearing to protect side bearing from damage.
Using inner bearing race installer tool No. J-37759 and driver handle tool No. J-8092, or equivalents, install pinion gear inner race.
Using outer bearing race installer tool No. J-37758 and driver handle tool No. J-8092 or equivalents, install pinion gear outer bearing race.
Set pinion depth as follows:
Lubricate inner and outer pinion bearings with GM part No. 1050010 or equivalent lubricant.
Fig. 8 Pinion Depth Measurement.
While holding pinion bearings in position, install a J-21777-102 gauge plate, J23597-12 inner pilot washer, J-21777-43 stud and nut and a J-21777-42 outer pilot washer, or equivalents as shown in Fig. 8 .
Hold stud stationary and torque locknut to 18 inch lbs.
Rotate gauge plate tool No. J-21777-102 or equivalent 25 revolutions to seat pinion bearings.
Torque locknut again to 18 inch lbs. to ensure bearings are seated.
Install two side bearing discs part No. J-21777-01, or equivalent, on side bearing bores using arbor tool No. J-23597-1, or equivalent.
Rotate gauge plate tool No. J-21777-102 until gauging areas are parallel with two side bearing discs.
Position dial indicator rod over the 97 mm portion of the gauging plate.
Connect dial indicator tool No. J-8001 or equivalent to arbor tool No. J-23597-1 and position gauge shaft over dial indicator rod.
Install side bearing caps and torque bolts to 63 ft. lbs.
Set dial indicator to zero.
Slowly rotate arbor on 97 mm step of gauge plate to determine the point of greatest deflection. Reset dial indicator to zero.
Slowly rotate arbor until dial indicator is no longer in contact with gauge plate.
Fig. 16 Pinion Depth Selective Shims.
Record dial indicator reading. This reading indicates the selective shim required for correct pinion depth. Refer to selective shim chart Fig. 16 for correct shim.
Install pinion selective shim on pinion gear shaft.
Using bearing installer tool No. J-6133-01, or equivalent, and a press pinion bearing on pinion gear shaft.
Install new collapsible spacer on pinion gear shaft.
Install pinion outer bearing into differential carrier.
Lubricate pinion oil seal with part No. 1050010, or equivalent, then install pinion oil seal using seal installer tool No. J-25273, or equivalent, and a plastic hammer.
Install pinion flange, washer and flange nut using pinion flange holder tool No. J-8614-01, or equivalent. Tightening flange nut will preload the pinion bearings. Exceeding preload specification will compress the collapsible spacer too far and require the installation of a new spacer. Adjust pinion bearing preload to 11 ft. lbs. starting torque not rotating torque. Measure pinion bearing preload again after rotating pinion several times to ensure bearings have been seated. If preload has been reduced, reset preload to specification .
Install side bearing races on differential side bearings.
Install differential case on differential carrier.
Install side bearing adjusters, then align bearing caps with marks made during disassembling and torque cap bolts to 65 ft.lbs.
Adjust backlash and differential bearing preload as follows:
Left bearing adjuster nut is located on ring gear side of carrier, right bearing adjuster nut is located on pinion gear side of carrier.
Using spanner wrench tool No. J-37760, or equivalent, loosen right adjuster nut until it does not contact side bearing race.
Using spanner wrench, tighten left adjuster nut until ring gear is fully engaged into pinion gear with zero backlash.
Ensure right adjuster nut is still not in contact with side bearing race.
Rotate pinion gear to ensure there is no binding.
Fig. 17 Side Bearing Preload Dial Indictor Setting.
Install dial indicator to differential carrier as shown in Fig. 17 .
Using spanner wrench too No. J-37760, or equivalent, tighten right adjuster nut until it contacts side bearing race.
Set dial indicator to zero against side bearing cap.
Adjust side bearing preload by tightening right adjuster nut until dial indicator reads 0.002-0.006, case spread.
Rotate pinion gear to ensure side bearings seat.