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Drive Pinion Depth

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  1. Drive pinion rear bearing shim thickness must be determined whenever a new axle housing, ring gear and pinion, or pinion bearings are installed. Shim pack thickness is determined by using Pinion Setting Gauge Set (J-21777). See Fig 1.
  2. Install pinion bearing races into housing (if previously removed). Install lubricated rear pinion bearing through rear of housing. Position Gauging Plate (J-21777-45 for 7.6" ring gear, J-45230 for 8.0" ring gear, J-21777-29 for 8.6" ring gear or J-21777-85 for 9.5" ring gear) to rear pinion bearing. Install stud bolt and washer through gauging plate and rear pinion bearing, pointing stud bolt toward front pinion bearing position. See Fig 1.
    Fig 1: Cross-Sectional View Of Pinion Setting Gauge Set
    G95H27265Courtesy of GENERAL MOTORS CORP.
  3. Install lubricated front pinion bearing into race. Install Bearing Disc (J-21777-42) to outside of front pinion bearing. Install and tighten stud bolt hex nut until snug. Rotate gauge plate and bearings to ensure proper seating, while snugging hex nut. Hold stud bolt head stationary with a wrench. Using INCH-lb. torque wrench, tighten hex nut in small increments until 15-25 INCH lbs. (1.7-2.8 N.m) of torque is required to rotate gauge plate and bearings. See Fig 1.
  4. Mount side bearing Gauging Discs (J-21777-45 for 7.6" ring gear, 8.0" and 8.6" ring gear or J-21777-86 for 9.5" ring gear) on ends of arbor. Place arbor into carrier side bearing recesses making sure gauging discs are properly seated. Install side bearing caps and bolts. Snug tighten bolts to avoid arbor movement.
  5. Position dial indicator on mounting post of arbor with contact button resting on top surface of plunger. Set dial indicator to zero. Push indicator down on indicator shaft until needle rotates 3/4 of a revolution to right, and then tighten in this position.
  6. Place plunger onto gauging area of pinion gauge plate. Rock plunger rod slowly back and forth across gauging area until dial indicator reads greatest deflection.
  7. At point of greatest deflection, set indicator to zero. Repeat rocking action several times to verify setting. Once zero reading is obtained, rotate gauge shaft to remove plunger from gauging area.
  8. Dial indicator will now read required pinion shim thickness for nominal pinion setting. Record this reading. Check drive pinion for painted or stamped markings on pinion stems, or for a stamped code number on small end of pinion gear.
    9. NOTE: If no markings are found on pinion, use dial indicator reading as shim thickness.
  9. If marking is a plus (+), add that many thousandths of an inch to recorded indicator reading. If marking is a minus (-), subtract that many thousandths of an inch from indicator reading. This measurement will then be required thickness of rear pinion bearing shim pack.
  10. Remove bearing caps and all gauging tools from housing. Place selected shim pack on pinion gear. Using a press, install lubricated pinion bearing onto pinion shaft.
  11. Install a NEW collapsible spacer over pinion gear shaft. Install pinion assembly into position from rear of housing. While holding pinion in position, carefully drive front pinion bearing onto pinion gear shaft until a few threads are exposed.
  12. Install pinion seal, pinion flange, washer and nut. Ensure pinion flange alignment mark is properly aligned with pinion shaft end mark. Using Companion Flange Holder/Remover (J-8614-01), tighten pinion self-locking nut until all end play is removed. Rotate pinion several times to seat bearings. Check preload using an INCH-lb. torque wrench.
  13. Continue tightening nut and checking preload until specified preload is obtained. See AXLE ASSEMBLY SPECIFICATIONS . DO NOT back off nut to lessen preload.
  14. If preload is exceeded, install a NEW collapsible spacer and retighten self-locking nut until proper preload is obtained.
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