S15/T15 Jimmy 2WD L4-119 1.9L VIN A 2-BBL (1983)
Carrier Pinion Shaft: Technical Service Bulletins
Differential Pinion Cross Shaft - R&R When Broken
Number:
83-T-91
Section:
IV
Date:
OCT., 1983
Subject:
DIFFERENTIAL CASE PINION CROSS
SHAFT REMOVAL PROCEDURE WITH A BROKEN PINION SHAFT LOCK SCREW
ALL REAR WHEEL DRIVE MODELS - ALL YEARS
TO:
ALL CHEVROLET DEALERS
The following procedure should be used to remove a broken differential pinion cross shaft lock screw. SAFETY GLASSES MUST BE WORN.
FIGURE 1 - DIFFERENTIAL CASE
STANDARD DIFFERENTIAL
1.
Install puller such as J-22888 or equivalent with the puller jaws inserted into the case openings and puller screw against the end of the pinion cross
shaft on the side of the case opposite the lock screw (refer to Figure 1). This is necessary so shearing the lock screw will not distress the pinion
gear surface inside the case. A spacer such as a 5/16" nut may be required
between the puller screw and the pinion cross shaft.
2.
Position the case assembly on an angle so pinion cross shaft will clear pinion gear head during removal procedure.
3.
Tighten puller screw to 50-55 lbs.ft. (68-75 N-m). Tap end of puller once with a hammer. Retighten puller screw about 1/8 turn (50-55 lbs.ft.
[68-75 N-m.]) and tap again. Repeat procedure until pinion cross shaft shears the lock screw.
NOTICE:
Too severe of a hammer blow may damage carrier side bearings.
4.
When the lock screw is sheared, remove puller, turn case assembly and remove pinion cross shaft. The remainder of the lock screw can then
usually be removed with a prick punch. A slight metal distress from lock screw hole to outer portion of case is acceptable. If case is broken out at
lock screw hole area, the case must be replaced.
5.
Install new parts as required and reassemble differential.
LIMITED SLIP DIFFERENTIAL
A limited slip differential case assembly does not have access for both puller jaws.
As the lock screw hole in the pinion cross shaft is within .150" from the end of shaft, a die grinder with a 1/4" carbide bit can be used to grind a groove
through the end of the pinion cross shaft exposing the lock screw. A 1/4" die grinder is a commonly available 28,000 to 30,000 RPM tool similar to a
router. Both electric and air powered die grinders are available from power tool sources. This tool and bit is also useful for elongating holes in steel, etc.
