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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1612 (Rear Drive Axle) >> Repair Instructions >> Determining Total Shim Pack Size

Determining Total Shim Pack Size

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required 

  1. Remove the differential side bearing shims. Refer to Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles)  or Drive Pinion Bearings Replacement (9.75 Inch Axle)  or Drive Pinion Bearings Replacement (10.5 Inch Axle) .
  2. Determine the pinion position shim and the pinion preload shims, if necessary. Refer to Pinion Depth Adjustment (8.6 Inch, 9.5 Inch, 11.5 Inch Axles)  or Pinion Depth Adjustment (9.75 Inch Axle)  or Pinion Depth Adjustment (10.5 Inch Axle) .
  3. Install the differential side bearing without the side bearing shims by doing the following:
    1. 3.1. In order to protect the differential case, install the J 36597  in the case on the side opposite of the bearing installation.
    2. 3.2. Install the differential side bearing.
    3. 3.3. Install the J 24430  or the J 45900  (2) and the J 8092  (1) over the differential side bearing.
    4. 3.4. Drive the differential side bearing into position using the J 24430  or the J 45900  and the J 8092. 
      Fig 1: J 8092 & J 45900
      G01480842Courtesy of GENERAL MOTORS CORP.
  4. Install the differential assembly into the axle housing.
  5. Move the differential assembly to the left until the left differential side bearing is against the left side bearing bore.
    IMPORTANT: Install the bearing caps into the same position from which each was removed.
  6. Install the left side bearing cap.
    NOTE: Refer to FASTENER NOTICE .
  7. Install the left side bearing cap bolts.

    Tighten 

    Tighten the bearing cap bolts finger tight. Do not torque the bolts to specification at this time.

  8. While holding the differential assembly against the left side bearing bore, press the right side bearing cup against the right differential side bearing.
    IMPORTANT: In order to accurately measure the differential side bearing shim thickness, the differential side bearing cup must be evenly seated against the differential side bearing.
  9. Using a feeler gauge, measure the distance between the right side bearing cup and the right side bearing bore. Use progressively larger feeler gauge sizes until a moderate drag is felt. Repeat this step several times while rotating the differential case in order to obtain a consistent reading.

    This measurement, measurement a, is the total shim pack thickness for the differential assembly without preload.

    Fig 2: Measuring Distance Between Right Side Bearing Cup & Right Side Bearing Bore
    G01480843Courtesy of GENERAL MOTORS CORP.
    CAUTION: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.
  10. Remove the left side bearing cap bolts.
  11. Remove the left side bearing cap.
  12. Install the right side bearing cap.
  13. Install the right side bearing cap bolts.

    Tighten 

    Tighten the bearing cap bolts finger tight. Do not torque the bolts to specification at this time.

  14. While holding the differential assembly ring gear against the drive pinion, press the left side bearing cup against the left differential side bearing.
    IMPORTANT: In order to accurately measure the differential side bearing shim thickness, the differential side bearing cup must be evenly seated against the differential side bearing.
  15. Using a feeler gauge, measure the distance between the left side bearing cup and the left side bearing bore. Use progressively larger feeler gauge sizes until a moderate drag is felt. Repeat this step several times while re-positioning the differential case in order to obtain a consistent reading.

    This measurement, measurement b, is the left side shim pack thickness for the differential assembly without preload.

    Fig 3: Measuring Distance Between Left Side Bearing Cup & Left Side Bearing Bore
    G01480844Courtesy of GENERAL MOTORS CORP.
  16. In order to determine the right side shim pack thickness, subtract the left side measurement, measurement b, from the total shim pack measurement, measurement a.

    This measurement is the thickness for the right side shim pack without preload or setting the initial backlash.

  17. Remove the right side bearing cap bolts.
  18. Remove the right side bearing cap.
  19. Remove the differential assembly.
  20. Determine the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment (8.6 Inch Axle)  or Differential Side Bearing Preload Adjustment (9.5 Inch Axle)  or Differential Side Bearing Preload Adjustment (9.75 Inch Axle)  or Differential Side Bearing Preload Adjustment (10.5 Inch, 11.5 Inch Axles) .
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