Necessary equipment
- DT-48200 Gearbox housing fastener with final drive assembly
- DT-48241 Gearbox Housing Bearing Race Plate with Final Drive Assembly
- DT-48242 Clutch Housing Bearing Race Plate
1. Using a rubber mallet, lightly tap the mating surface of the gearbox housing with the final drive assembly to ensure that the bearings are fully seated.
2. Install DT-48200 into the gearbox housing with the final drive assembly.
3. Using DT-48200 and a height gauge, adjust the zero point setting for each location on the transaxle housing flange surface.
Important: To set the zero point, adjust the height of DT-48200.
4. Using a height gauge, measure in three places on the surface of the secondary shaft gear thrust ring. (Average = A)
- The height from the surface of the gearbox housing flange with the final drive assembly to the surface of the thrust ring.
5. Position the clutch housing differential bearing race, differential, transmission housing differential bearing race with final drive assembly and DT-48241 on DT-48242 (for four-wheel drive) or DT-48534 (for all-wheel drive).
6. Using a height gauge, adjust the zero point setting for each location on the differential bearing race surface of the gearbox housing with the final drive assembly.
7. Measure with a height gauge at three places on the surface of the differential gear epicyclic gear. (Average = B)
- The height from the differential bearing race of the gearbox housing with the final drive assembly to the surface of the differential epicyclic gear.
8. Using an altimeter, take measurements at three locations on the DT-48242 (for four-wheel drive) or DT-48534 (for all-wheel drive).
- Height from the differential bearing race of the gearbox housing with the final drive assembly to the differential bearing ring of the clutch housing.
9. To obtain the shim size for the transmission housing with the final drive assembly, use the following formula.
S1 (For FWD and AWD) = 62.92 mm - A - B
10. To obtain the clutch housing shim size, use the following formula:
S2 (For FWD) = 156.84 mm - C - S1
S2 (For AWD)= 158.09 mm - C - S1
ADJUSTING SHIM CHARACTERISTICS (Tolerance: -0.03)
- For four-wheel drive - the size of the gasket for the clutch housing and gearbox housing with the main gear assembly.
- For all-wheel drive - the gasket size for the gearbox housing with the final drive assembly.
(Unit: mm)
|
Part number
|
Adjusting shim size
|
Part number
|
Adjusting shim size
|
|
96420170
|
0.50
|
96420161
|
0.95
|
|
96420169
|
0.55
|
96420160
|
1.00
|
|
96420168
|
0.60
|
96420159
|
1.05
|
|
96420167
|
0.65
|
96420158
|
1.10
|
|
96420166
|
0.70
|
96420157
|
1.15
|
|
96420165
|
0.75
|
96420156
|
1.20
|
|
96420164
|
0.80
|
96420155
|
1.25
|
|
96420163
|
0.85
|
96420154
|
1.30
|
|
96420162
|
0.90
|
96420153
|
1.35
|
ADJUSTING SHIM CHARACTERISTICS (Tolerance: -0.03)
- For all wheel drive - clutch housing gasket size.
(Unit: mm)
|
Part number
|
Adjusting shim size
|
Part number
|
Adjusting shim size
|
|
96420188
|
0.50
|
96420179
|
0.95
|
|
96420187
|
0.55
|
96420178
|
1.00
|
|
96420186
|
0.60
|
96420177
|
1.05
|
|
96420185
|
0.65
|
96420176
|
1.10
|
|
96420184
|
0.70
|
96420175
|
1.15
|
|
96420183
|
0.75
|
96420174
|
1.20
|
|
96420182
|
0.80
|
96420173
|
1.25
|
|
96420181
|
0.85
|
96420172
|
1.30
|
|
96420180
|
0.90
|
96420171
|
1.35
|
Information taken from the official website: ChevyMan.ru