Tahoe 4WD V8-393 6.5L DSL Turbo VIN S (1995)
1.
Mark differential case halves for proper assembly.
2.
Remove bolts holding case and cover together.
Ring gear is mounted on case.
3.
Separate cover from case and remove differential side gears and thrust washers, pinion gears and thrust washers, and differential spider.
INSPECTION
1.
Thoroughly wash all parts in suitable solvent.
2.
Inspect ring gear for chipped, scored, or worn teeth.
3.
Check radial clearance between differential side gears and differential case and the fit of differential pinions on spider.
4.
Inspect spider arms for wear or distortion.
5.
Inspect teeth and splines of differential pinions and side gears for chipping or excessive wear.
6.
Check thrust washers for wear, replacing if any signs of wear are evident.
7.
Check differential side bearings and cups for broken races, discoloration, or roughness.
8.
Inspect differential case for cracks or distortion.
RING GEAR, REPLACE
1.
Remove ring gear from case by tapping rear of gear with soft faced hammer.
2.
Inspect ring gear pilot case flange and rear of ring gear for dirt or burrs.
3.
Fabricate two guide pins by cutting heads off of suitable cap screws and slotting ends.
4.
Install guide pins to new gear diametrically opposite each other.
5.
Start guide pins through case flange and tap ring gear onto case.
DIFFERENTIAL BEARING, REPLACE
1.
Install tool J-8107 or equivalent, ensuring that tool legs are securely fitted in notches in case, and tighten retaining yokes.
2.
Tighten puller screw to remove bearing.
3.
Position new bearing on hub with thick side of inner race facing case and install bearing using tool J-1488 or equivalent.
Side bearing tool is
counterbored and has pilot to assure proper installation and seating of bearing.
DIFFERENTIAL, ASSEMBLE
1.
Lubricate differential side gears, pinions, and thrust washers with suitable lubricant.
2.
Place differential pinions and thrust washers on spider.
3.
Assemble side gears, pinions, and thrust washers to left half of differential case.
4.
Assemble case halves, ensuring that marks made during disassembly are aligned.
5.
Install differential to ring bolts and lockwashers and tighten evenly until ring gear is flush with case flange.
6.
Remove two guide pins and install remaining bolts, then torque all bolts alternately and evenly to 105 ft. lbs.
Disassembly
