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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1024 (Drive Axle - Locking/Limited Slip) >> Repair Instructions >> Locking Differential Adjustment (9.5 Inch Axle) >> Thrust Block Clearance Adjustment

Thrust Block Clearance Adjustment

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT: The left and right side gear backlash measurements must be done before the thrust block measurement can be completed.
  1. Install the locking differential side gear thrust washer into the differential case.
    2. Fig 1: View Of Left Side Gear Thrust Washer
    GM790754Courtesy of GENERAL MOTORS CORP.
  2. Install the left side locking differential side gear cam unit and clutch disc assembly into the differential case.
    3. Fig 2: View Of Left Side Gear Cam Unit & Clutch Disc Assembly
    GM790759Courtesy of GENERAL MOTORS CORP.
  3. Install the right side differential side gear shim into the differential case.
  4. Install the right side locking differential side gear and clutch disc assembly into the differential case.
  5. Install the pinion shaft.
  6. Install the pinion shaft bolt.

    Tighten:  Tighten the pinion shaft bolt finger tight.

  7. Install a brass drift between the left side gear and the pinion shaft.

    Press the brass drift in far enough in order to compress the clutch disc assembly and hold the left side gear assembly in place.

    8. Fig 3: Installing Brass Drift Between Locking Differential Side Gear & Pinion Shaft
    GM790751Courtesy of GENERAL MOTORS CORP.
  8. Install a brass drift between the right side gear and the pinion shaft.

    Press the brass drift in far enough in order to hold the right side gear assembly in place.

    9. IMPORTANT: Do not measure the distance between the side gear teeth.
  9. Measure the distance between the side gear faces using a 25.4-50.8 mm (1-2 in) telescoping gage.
    10. Fig 4: Measuring Distance Between Side Gear Faces
    GM790765Courtesy of GENERAL MOTORS CORP.
  10. Remove the telescoping gage.
  11. Measure the telescoping gage with a micrometer.

    Record the measurement.

  12. Compare the measurement obtained in step 11 to the thrust block sizes available. If the measurement is equal to one of the thrust blocks sizes available, then select that thrust block.
  13. If the measurement obtained in step 11 is not equal to one of the thrust blocks sizes available, then select the thrust block that is smaller than the measurement.

    For example, if the measurement is 40.869 mm (1.609 in), select the 40.792 mm (1.606 in) thrust block.

    14. IMPORTANT: The backlash must be rechecked and adjusted to specification anytime the left and/or the right thrust washers are replaced.
  14. If the measurement obtained in step 11 is less than 40.488 mm (1.594 in), then reduce the left side gear thrust washer or the right side gear shim thickness in order to increase the thrust block opening.
  15. If the measurement obtained in step 11 is greater than 41.120 mm (1.622 in), then increase the left side gear thrust washer or the right side gear shim thickness in order to decrease the thrust block opening.
  16. Recheck the left and/or right side gear backlash and adjust as necessary.
  17. Recheck the thrust block clearance and adjust as necessary.
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