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Home >> Geo >> 1997 >> Tracker Base, 4D Utility, 4WD, Standard >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Differentials & Axle Shafts >> Overhaul >> Front & Rear Differential Assemblies >> Reassembly & Adjustments

Reassembly & Adjustments

  1. On rear differentials, install rear wheel anti-lock brake exciter ring to differential case using Exciter Ring Installer (J-38891), Differential Side Bearing Pilot (J-8107-04) and press. Pressure exerted on exciter ring should not exceed 1103 lbs. (500 kg).
  2. Ensure press fit is applied evenly around perimeter of exciter ring. Install wheel speed sensor. On front or rear differentials, install differential pinion gears, thrust washers and side gear with selective shim in differential case. See Fig 1 .
    Fig 1: Identifying Side Gear Selective Shim
    G92D01548Courtesy of GENERAL MOTORS CORP.
  3. Using dial indicator, measure differential side gear end play. See Fig 2 . If end play is not .005-.014" (.12-.37 mm), select another shim to obtain correct end play.
  4. Install roll pins into differential case until flush with differential case surface. Install differential side gear, selective shim and ring gear to differential case.
  5. Tighten ring gear bolts to specification. See TORQUE SPECIFICATIONS  . Using dial indicator with plunger extension and Universal End Play Measuring Tool (J-35138), measure differential side gear end play. See Fig 3 . If end play is not .005-.014" (.12-.37 mm), select another shim to obtain correct end play.
    Fig 2: Measuring Side Gear End Play (Pinion Gear Side)
    G92F01549Courtesy of GENERAL MOTORS CORP.
    Fig 3: Measuring Side Gear End Play (Ring Gear Side)
    G92H01550Courtesy of GENERAL MOTORS CORP.
    NOTE: After proper end play is obtained, remove ring gear bolts and install Loctite 414 to threads of ring gear bolts. Install ring gear bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  6. Using Bearing Installer (J-24433) with Driver Handle (J-8092), press differential side bearings on to case. Using Inner Bearing Race Installer (J-37759) with Driver Handle (J-8092), press pinion gear inner and outer bearing races into differential carrier.
  7. Lubricate inner and outer pinion bearings with GM Axle Lubricant (1051344). While holding pinion bearings in position, install Gauge Plate (J-21777-102), Inner Pilot Washer (J-23597-12), Stud and Nut (J-21777-43), and Outer Pilot Washer (J-21777-42). See Fig 4 .
    Fig 4: Measuring Pinion Depth (Typical)
    G92J01551Courtesy of GENERAL MOTORS CORP.
  8. Hold stud stationary, and tighten lock nut to 18 INCH lbs. (2 N.m). Rotate gauge plate 25 revolutions to seat pinion bearings. To ensure bearings are seated, tighten lock nut again to 18 INCH lbs. (2 N.m).
  9. Install 2 Side Bearing Discs (J-21777-101) on side bearing bores with Arbor (J-23597-1) installed through side bearing discs. Rotate gauge plate until gauging areas are paralleled with both side discs.
  10. On front differentials, position dial indicator rod over 97-mm portion of gauge plate. On rear differentials, position dial indicator on 97-mm portion of gauge plate.
  11. On front or rear differentials, connect dial indicator to arbor. Position gauge shaft over dial indicator rod. Install side bearing caps and tighten to specification. See TORQUE SPECIFICATIONS  .
  12. Set dial indicator to zero. On front differentials, slowly rotate arbor on 97-mm step of gauge plate to determine point of greatest deflection, and reset dial indicator to zero. See Fig 4 .
  13. On rear differentials, slowly rotate arbor on 97-mm step of gauge plate to determine point of greatest deflection, and reset dial indicator to zero. On front or rear differentials, slowly rotate arbor until dial indicator is no longer on gauge plate. See Fig 4 .
  14. Record dial indicator reading. This reading indicates selective shim required for correct pinion depth. Select appropriate shim thickness. Shims are available from .012 (.30 mm) to .050" (1.27 mm).
  15. Install pinion pre-selected shim on pinion gear shaft. Using Bearing Installer (J-6133-01) and press, install inner bearing on pinion gear shaft. Install new collapsible spacer on pinion gear shaft with short shank toward pinion.
  16. Install outer pinion bearing in differential carrier. Using Oil Seal Installer (J-25273), install pinion oil seal. Apply lubricant to oil seal lip. Install pinion flange, washer and flange nut using Pinion Flange Holder (J-8614-01).
    CAUTION: Tightening pinion flange nut will preload pinion bearings. Exceeding preload specification will compress collapsible spacer too far, and will require replacement of collapsible spacer.
  17. Tighten pinion flange nut in increments of 44 INCH lbs. (5 N.m). Between each increment, remove flange holder and rotate pinion flange 5 turns. Continue this procedure until bearing preload starting torque is 11 INCH lbs. (1.2 N.m). Measure pinion bearing preload again after rotating pinion 5 turns to ensure bearings are seated.
  18. Tighten pinion nut gradually until starting torque specification is obtained and restake flange nut. Install side bearing races on differential side bearings. Install differential case on differential carrier.
  19. Install side bearing adjusters and bearing caps. Align caps with differential carrier match marks made during disassembly procedure. Tighten differential side bearing cap bolts to 30 ft. lbs. (40 N.m). Do not tighten differential side bearing cap bolts to final specification until side bearing preload and differential backlash have been correctly adjusted.
    NOTE: Side bearing adjuster nut are identified as ring gear side or pinion gear side.
  20. Using spanner wrench, loosen adjuster nut on pinion gear (left) side of differential until it does not contact side bearing race. Tighten adjuster nut on ring gear (right) side of differential until ring gear is fully engaged into pinion gear with zero backlash.
  21. Check adjuster nut on pinion gear side to ensure it still does not contact side bearing race. Rotate pinion gear to ensure no binding is evident. To adjust bearing preload, install dial indicator to differential case. See Fig 5 .
    Fig 5: Checking Side Bearing Preload
    G93C82851Courtesy of GENERAL MOTORS CORP.
  22. Using spanner wrench, tighten adjuster nut on pinion gear side until it contacts side bearing. Set dial indicator to zero against side bearing cap. Adjust side bearing preload by tightening adjuster nut on pinion side with spanner wrench until dial indicator reads .002-.006" (.05-.15 mm).
  23. To check gear backlash, install dial indicator to differential case. See Fig 6 . Hold pinion gear from turning and rock ring gear back and forth. If backlash is not .008-.015" (.20-.38 mm), use spanner wrench to loosen the appropriate adjuster nut and tighten opposite nut an equal amount. This will maintain side bearing preload.
    Fig 6: Adjusting Gear Backlash
    G92D01553Courtesy of GENERAL MOTORS CORP.
  24. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS  . Install bearing lock plates and tighten bolts to specification. See TORQUE SPECIFICATIONS  . Using gear marking compound, check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Stake pinion flange nut.
Fig 7: Exploded View Of Front Differential Assembly
G92F01554Courtesy of GENERAL MOTORS CORP.
Fig 8: Exploded View Of Rear Differential Assembly
G92I01555Courtesy of GENERAL MOTORS CORP.
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