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Drive Pinion Depth

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NOTE: Pinion flange/yoke holder may also be referred to as pinion flange holder /remover.
NOTE: Drive pinion rear bearing shim thickness must be determined whenever a NEW axle housing, ring gear and pinion, or pinion bearings is installed.
  1. Assemble the pinion bearing installer bolt and bearing disc. Install outer pinion bearing onto the bearing installer and insert into the axle housing. Install the inner pinion bearing into the axle housing. Install the gauging plate onto inner pinion bearing and pinion bearing installer bolt. See Fig 1 .
  2. While holding the gauging plate stationary, tighten the nut on the installer bolt just until the end play between the pinion bearings is removed. Rotate the assembly several times in both directions in order to seat the pinion bearings.
  3. Using an inch-pound torque wrench, measure the rotating torque of the assembly. The rotating torque of the assembly should be 20-45 INCH lbs. (2.3-5.1 N.m). If the rotating torque of the assembly is less than specification, continue to tighten the pinion bearing installer nut until specified rotating torque is obtained.
    4. NOTE: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.
  4. Assemble gauging discs and arbor and install into axle housing. Install dial indicator onto arbor. See Fig 1 . Place the stem of the gauging discs, arbor and dial indicator assembly onto the bottom step of the pinion bearing installer.
  5. Install the side bearing caps and side bearing cap bolts. Tighten the side bearing cap bolts to specification. See TORQUE SPECIFICATIONS  . Rotate the gauging disc and arbor assembly. The arbor must rotate back and forth freely with the discs. If the assembly does not rotate freely, disassemble the components, inspect for proper seating and/or mis-aligned components and re-assemble.
  6. Loosely clamp the dial indicator onto the stem on the gauging plate. Place dial indicator contact pad onto the mounting post of the arbor. Loosen the lock nut on the dial indicator and push down until the needle has turned 3/4 of a turn clockwise.
  7. Tighten the dial indicator clamp finger tight. Move the plunger of the gauging discs, arbor and dial indicator assembly back and forth on the bottom step of the pinion bearing installer until the needle of the dial indicator indicates the greatest deflection. The deflection is the point where the needle changes direction. At the greatest point of deflection, move the indicator housing of the Dial Indicator (J-8001) until the needle indicates ZERO.
  8. Move the plunger of the dial indicator back and forth again to verify the ZERO setting. Adjust the housing of the dial indicator as necessary to set the needle to ZERO. Rotate the arbor away from the gauging plate. The value indicated is the amount of pinion shim thickness required for a nominal pinion setting.
  9. In order to adjust the pinion shim thickness for the drive pinion that is to be installed, read the number on the button end of the pinion. If the number on the button end of the pinion is "0", no adjustment of the pinion preload shim pack is necessary. If the number is not "0", the number will also have a corresponding "+" or "-" in front of it. The "+" or "-" indicates the amount of pinion preload shim thickness that either needs to be added to or subtracted from the amount determined in step  8 in order to the drive pinion gear to be positioned properly within the axle housing. For example, go to next step.
  10. For example, if the number on the button end of the pinion is a "+3", this indicates that 0.003" (0.0762 mm) of shim thickness will need to be subtracted from the value previously determined in step  8 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. If the number on the button end of the pinion is a "-3", this indicates that 0.003" (0.0762 mm) of shim thickness will need to be added to the value determined in step  8 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. Remove the pinion depth setting tools.
  11. Remove the pinion bearings. Install the pinion position shim onto the drive pinion. Measure the thickness of the shim with a micrometer in order to verify the thickness. Install the inner pinion bearing onto the drive pinion using Bearing Installer (J-24433).
  12. Install the original pinion preload shims onto the drive pinion. If the original shims are not available, assemble 0.060" (1.52 mm) of pinion preload shims to install. Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size. Install the drive pinion with the inner pinion bearing and the pinion preload shims into the axle housing.
  13. Install the outer pinion bearing. Install the outer pinion bearing. Install the thrust washer. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
  14. Install the pinion yoke nut washer. Install the pinion yoke nut. Tighten the pinion yoke nut to 186 ft. lbs. (252 N.m). Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Specification The rotating torque of the drive pinion should be between 20-45 INCH lbs. (2.3-5.1 N.m).
  15. If the rotating torque of the drive pinion is not within specifications, adjust the pinion preload shim thickness by doing the following: Install the Pinion Flange/Yoke Holder (J-8614-01) to the pinion yoke. Remove the pinion nut while holding the pinion flange/yoke holder. Remove the washer.
  16. Install pinion seal, pinion flange, washer and nut. Ensure pinion flange alignment mark is properly aligned with pinion shaft end mark. Using pinion flange/yoke holder, 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.
  17. Continue tightening nut and checking preload until specified preload is obtained. See AXLE ASSEMBLY SPECIFICATIONS  . DO NOT back off nut to lessen preload.
  18. Remove the pinion yoke by turning pinion nut clockwise while holding the Pinion Flange Remover/Installer (J-8614-01). Apply a light coat of axle lubricant, GM P/N 12378557 or equivalent meeting GM Specification 9986207, to lip of the pinion seal. Install the NEW pinion oil seal using Seal Installer (J-45710).
  19. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Install the pinion yoke nut washer. Install the NEW pinion yoke nut. Tighten the pinion yoke nut to specification. See TORQUE SPECIFICATIONS  .
  20. Measure the rotating torque of the drive pinion using an INCH Lb. torque wrench. See Fig 2 . See AXLE ASSEMBLY SPECIFICATIONS  .
Fig 1: Cross-Sectional View Of Pinion Setting Gauge Set
G95H27265Courtesy of GENERAL MOTORS CORP.
Fig 2: Checking Drive Pinion Preload
G95J27275Courtesy of GENERAL MOTORS CORP.
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