Contents: Removal ↧ Installation ↧
Removal
Caution: Group and label the shims as they were originally installed. If you have removed or replaced the gearbox gears (main gear), adjust the bearing preload, engagement clearance and tooth contact pattern. If you have removed or replaced the differential cup without replacing any other parts, you can install the original shims in their original locations. However, always check the shape of the tooth contact pattern in the final drive.
1. Raise the vehicle.
2. Remove the rear wheels.
3. 8.6" and 9.5" gearboxes: Remove the brake calipers.
4. 8.6" and 9.5" gearboxes: remove the brake discs.
5. Remove the gearbox housing cover and cover gasket.
6. Remove the axle shafts.
7. Remove the bearing adjusting nut retainer (9.5" and 10.5" gearboxes - right).
8. Loosen the mounting bolts and remove the differential bearing caps. Mark the caps with their installation locations.
9. 8.6-inch gearbox: Remove the gearbox using the lever installed in the differential cup window.
Note: When removing the gearbox, do not damage the sealing surfaces of the gearbox housing cover.
10. 9.5-inch and 10.5-inch gearboxes: using a special key, loosen the differential bearing adjusting nuts and remove the gearbox.
11. If necessary, remove the outer bearing rings, adjusting washers and spacers. Mark the installation locations of the removed parts.
12. If necessary, remove the differential side bearing races.
13. If necessary, remove the driven gear of the gearbox.
Installation
1. If removed, install the driven gear of the gearbox.
2. If removed, install the differential side bearing races.
3. Lubricate the differential bearings with transmission oil.
4. Install the gearbox into the gearbox housing.
5. Install the differential bearing caps and their mounting bolts. Hand tighten the bolts.
6. On 9.5" and 10.5" gearboxes, tighten the bearing adjusting nuts evenly until they contact the bearing race.
7. Adjust the differential side bearing preload.
8. Adjust the clearance in the main gear engagement.
9. Check the shape and position of the contact patch of the main gear teeth.
10. Tighten the bearing cap bolts.
Tightening torque:
- 8.6 inch gearbox - 75 Nm.
- 9.5 inch gearbox - 85 Nm.
- 10.5 inch gearbox - 185 Nm.
11. Install the axle shafts.
12. Install the new gasket and gearbox housing cover.
13. 8.6" and 9.5" gearboxes: install brake discs.
14. 8.6" and 9.5" gearboxes: install brake calipers.
15. Install the rear wheels.
16. Fill the gearbox housing with transmission oil.
17. Lower the vehicle.
The article is reprinted from the website «ChevyMan»