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Drive Axles - Front: Adjustments Chevrolet Silverado 2500

Differentials & Drive Axles 9 illustrations ~1562 words

Adjustment Method

The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced

  1. The inner axle shaft
  2. The inner axle shaft housing
  3. The clutch shaft
  4. The differential carrier case
  5. The ring and pinion gears
  6. The differential case assembly
  7. The bearings
  8. The carrier connector

Front drive axle clutch shims are available in the following sizes

Scheme 332

Scheme 332
Scheme 332

Scheme 333

Scheme 333
Scheme 333

Scheme 334

Scheme 334
Scheme 334

Scheme 335

Scheme 335
Scheme 335
  1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S40572842342008110500000) .
  2. Install the following components into the inner axle shaft housing: Install the inner axle shaft (1) into the front drive axle housing (4). Install the thrust washer (with tabs) (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing. Install the thrust washer (without tabs) (6). Install the retaining ring (7) into the front drive axle clutch gear (6).
  3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. IMPORTANT: In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring.
  4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go.
  5. Install the J 34673 (1) and the J 34672 (2) onto the inner shaft housing as shown.
  6. Using the J 34672 , measure the distance from the edge of the inner axle shaft to the surface of the J 34673 . Ensure the base of the J 34672 is flat against the inner axle shaft.
  7. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft.
  8. Subtract the measurement obtained in step 6 from the measurement obtained in step 7. This measurement is the distance between the inner axle shaft and the clutch shaft before subtracting the J 34673 .
  9. Using a micrometer, measure the thickness of the J 34673 .
  10. Subtract the thickness of the J 34673 , measured in step 9, from the measurement determined in step 8. This is the shim thickness for the front axle without having any axle shaft endplay.
  11. The correct shim size will be one size smaller than the figure obtained in the previous step. Note the following examples: If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim. If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim.

Alternate Adjustment Method

Important: Use this method only if the proper tools for calculating the shim size are unavailable.

Scheme 336

Scheme 336: Alternate Adjustment Method
Scheme 336: Alternate Adjustment Method
  1. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place.
  2. Install the assembled axle tube and the shaft to the carrier. Do not use sealer at this time. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
  3. Install the bolts. Tighten Tighten the bolts to 40 N.m (30 lb ft).
  4. Measure the shaft end play using the following procedure: Install the J 8001 or the equivalent on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange. Move the shaft back and forth and read the end play. The correct end play is 0.03-0.51 mm (0.001-0.020 in). If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.

Adjustment Procedure

Important: Make sure all of the tools, the pinion bearings, and the pinion bearing cups are clean before proceeding.

Scheme 337

Scheme 337: Adjustment Procedure
Scheme 337: Adjustment Procedure

Scheme 338

Scheme 338
Scheme 338
  1. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. see scheme 2
  2. Install the J 36601-4 or the J 36601-3 (4) to the J 36601-7 (1).
  3. Install the J 21777-35 for the 8.25 inch axle or the J 21777-8 for the 9.25 inch axle (3) to the J 36601-7 (1).
  4. Install the inner pinion bearing into the differential carrier case half.
  5. Insert the J 36601-7 (1) with the J 21777-35 or the J 21777-8 (3) through the inner pinion bearing and the differential carrier case half.
  6. Install the outer pinion bearing.
  7. While holding the outer pinion bearing in position, install the J 36601-5 (2), the washer, and the nut to the J 36601-7 (1).
  8. While holding the J 36601-7 (1) stationary with a wrench, tighten the nut on the J 36601-7 (1). Tighten Tighten the nut until all of the end play is removed from the J 36601.
  9. Rotate the assembly several times in both directions in order to seat the pinion bearings.
  10. While holding the J 36601-4 or the J 36601-3 (4) stationary, measure the rotating torque of the J 36601 using an inch-pound torque wrench. Specification The rotating torque of the J 36601 should be between 1.1-2.3 Nm (10-20 lb in).
  11. If the torque is less than 1.0 Nm (10 lb in), continue to tighten the nut on the J 36601-7 until a rotating torque of 1.1-2.3 Nm (10-20 lb in) is obtained.
  12. Install the adjustment screw and the lock nut of the J 29763 (2) to the J 36601-4 or the J 36601-3. see scheme 195: Using J 36601-3 & J 29763 To Measure Lowest Point In The Differential Side Bearing Bore
  13. Install the J 29763 to the adjustment screw and lock nut assembly. Tighten the lock nut to hold the J 29763 in place.
  14. Place the contact pad of the J 36601-4 or to the J 36601-3 into the differential side bearing bore.
  15. Adjust the J 29763 to the differential bearing bore by doing the following: Loosen the lock nut on the J 29763. Place the contact pad of the J 36601-4 or the J 36601-3 onto the differential side bearing bore. With the contact pad of the J 36601-4 or the J 36601-3 touching the differential side bearing bore, push down on the J 29763 until the needle of the J 29763 has turned 3/4 of a turn clockwise.
  16. Rotate the J 36601-4 or the J 36601-3 (1) back and forth until the needle of the J 29763 (2) indicates the lowest point in the differential side bearing bore.
  17. At the lowest point of deflection, move the housing of the J 29763 until the needle indicates ZERO.
  18. Move the J 36601-4 or the J 36601-3 back and forth again to verify the zero setting. Adjust the housing of the J 29763 as necessary to set the needle to ZERO.
  19. After the ZERO setting is obtained and verified, grasp the J 36601-4 or the J 36601-3 (1) by the flats and move the J 36601-4 or the J 36601-3 out of the differential side bearing bore. see scheme 196: Using J 36601-3 & J 29763 To Measure Thickness Of The Shim Needed In Order To Set The Depth Of The Pinion
  20. The value indicated on the J 29763 (2) is the thickness of the shim needed in order to set the depth of the pinion.
  21. Select the shim that indicates the correct thickness. Measure the shim with a micrometer in order to verify that the thickness is correct.
  22. Remove the pinion depth setting tools.
  23. Remove the pinion bearings.
  24. Install the pinion shim between the drive pinion and the inner pinion bearing and assemble the differential carrier. Refer to Differential Carrier Assembly Assemble.

Differential Pinion Gear Shims Sizes. Scheme 339

Scheme 339: Differential Pinion Gear Shims Sizes
Scheme 339: Differential Pinion Gear Shims Sizes

ADJUSTMENTS AFFECTING TOOTH CONTACT

The following 2 adjustments affect the tooth contact pattern

  1. Backlash adjustment
  2. Pinion depth adjustment

The effects of bearing preloads are not readily apparent on hand-loaded tooth contact pattern tests. However, bearing preloads should be within specifications before proceeding with backlash and pinion depth adjustments.

Pinion Depth Adjustment

Adjust the position of the pinion by increasing or decreasing the distance between the pinion head and the centerline of the ring gear. Decreasing the distance moves the pinion closer to the centerline of the ring gear. Increasing the distance moves the pinion farther away from the centerline of the ring gear.

Backlash Adjustment

Adjust the backlash by means of moving the side bearing adjuster sleeves which move the case and ring gear assembly closer to or farther from the pinion. Also use the adjuster sleeves in order to set the side bearing preload.

  1. If the left side adjuster sleeve is moved in, along with an equal outward movement of the right side adjuster, the backlash will increase.
  2. If the left side adjuster sleeve is moved out, along with an equal inward movement of the right side adjuster, the backlash will decrease.

Scheme 340

Scheme 340: TESTING PROCEDURE
Scheme 340: TESTING PROCEDURE
  1. Wipe clean the differential case, the ring gear and the differential carrier housing of lubricant. Carefully clean each tooth of the ring gear.
  2. Use a medium stiff brush in order to sparingly apply gear marking compound GM P/N 1052351 (Canadian P/N 10953497) or equivalent to all of the ring gear teeth.
  3. Using a wrench, turn the drive pinion flange/yoke so that the ring gear rotates at least 3 full revolutions.
  4. Turn the drive pinion flange/yoke in the opposite direction so that the ring gear rotates at least 3 full revolutions in the opposite direction.
  5. Observe the pattern on the ring gear teeth. Compare the pattern with the following illustrations.

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