1967 CHEVROLET CAMARO air suspension

REAR SUSPENSION AND DRIVE LINE 4-25

Fig.
69—Removing Crossmember (Corvette)

4.
Remove bolts securing carrier cover to cross-

member.

5.
Inspect rubber isolation mounts for aging and re-

place where necessary.

Repairs—Isolation Mount

1.
Bend back isolation mount tabs to allow mount re-

moval (fig. 70).

2.
Place crossmember on a suitable support and press

mount out of arm using a piece of suitable size pipe

or tubing on outer shell or inner insert.

3.
Place new mount into position on crossmember,

compress outer sleeve and press mount into place

until it is fully and squarely seated.

4.
After installation, bend over locking tabs.

Installation

1.
Install carrier cover to crossmember and torque

bolts to specifications.

2.
Raise crossmember into position and install mount-

ing bolts. Torque bolts to specifications.

3.
Install differential carrier assembly as outlined

under Differential Carrier
-
Installation in this

section.

4.
Install wheels and tires, remove frame supports and

lower vehicle.

STABILIZER SHAFT REPLACEMENT

1.
Raise rear of vehicle and support at frame side rail

with stand jacks.

2.
Disconnect stabilizer shaft at both torque arms (fig.

71).
Remove stabilizer shaft brackets from the

frame and withdraw assembly from vehicle.
ISOLATION MOUNT

CROSSMEMBER

BEND OVER TABS AFTER INSTALLATION

Fig.
70—Crossmember Mount Cross-Section (Corvette)

3.
Inspect bushings for signs of deterioration, and in-

spect shaft for bends, breaks or other defects - do

not attempt to straighten shaft - replace parts as

deemed necessary.

4.
Position bushings on shaft and loosely install shaft

to torque arms and at frame brackets.

5.
Align shaft to assume proper placement when bolts

are torqued, and torque attaching bolts to

specifications.

Fig.
71—Stabilizer Shaft Installation (Corvette)

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION
AND
DRIVE LINE
4-26

DRIVE LINE

REAR AXIE

INDEX

Page

General
Description
4-26

Chevrolet,
Camaro,
Chevelle
and
Chevy
II 4-26

Corvette
4-26

Maintenance
and
Adjustments
4-27

Lubricant
4.37

Lubricant'
Leaks
4_27

Axle Bolts
and
Wheel
Nuts
4-27

Rear Axle Noise
Diagnosis
4-29

Gear Noise
4_29

Bearing
Noise
4-29

Failure
Analysis
4^9

Hypoid
Gears
4..3Q

Differential Gears. 4_30

Bearings
....'.
4.30

Component Parts Replacement

(Chevrolet, Chevelle, Camaro and Chevy n ..... 4.30

Axle Assembly ,. . 4_30

Removal 4 30

Installation * ' 4 3Q
Axle Shaft . . . 4-31

Removal 4-31

Wheel Bolt Replacement 4-31

Oil Seal and/or Bearing Replacement. 4-31

Brake Flange Plate Replacement 4-31

Installation 4-32

Pinion Flange, Dust Deflector and/or

Oil Seal Replacement 4-32

Component Parts Replacement (Corvette) 4-34

Axle Driveshaft .- 4-34

Removal 4-34

Repairs 4-34

Installation. . 4-34

Pinion Flange, Dust Deflector and/or Oil Seal. .... 4-35

Removal 4-35

Inspection . 4-35

Installation .- 4-35

Differential Carrier 4-36

Removal 4-36

Installation 4-36

Positraction Differential Unit-On the Vehicle Check . . 4-37

\

GENERAL DESCRIPTION

CHEVROLET, CHEVELLE, CHEVY
I! AND
CAMARO

The rear axle
(fig. 72) is a
semifloating, fabricated

construction type consisting
of a
cast carrier with large

bosses
on
each
end
into which
two
welded steel tubes

are fitted.
The
carrier contains
an
overhung hypoid

pinion
and
ring gear.
The
differential
is a
two pinion

arrangement.

The axle housing
is
made up
of
two steel welded tubes

pressed into
the
crossbore
of the
cast carrier
-
each

tube
is
puddle welded
at
three places
to the
carrier.

Welded-on brackets provide attachment points
for

Chevelle springs,; shock absorbers,
and
lower control

arms.
Chevrolet models have welded-on brackets
for

control arms,
tie
rod, and shock absorbers. The housing

on Chevy II and Camaro has welded brackets
for
mounting

lower spring
pad
and shock absorber.
A
welded flange
is

provided
for
brake flange plate attachment.

The overhung hypoid drive pinion
is
supported
by
two

preloaded tapered roller bearings.
The
pinion shaft
is

sealed
by
means
of a
molded, spring loaded, rubber seal.

The seal
is
mounted
on the
pinion shaft flange which
is

splined and bolted
to
the hypoid pinion shaft.

The hypoid ring gear
is
bolted
to a
one-piece differen-

tial case which
is
supported
by two
preloaded tapered

roller bearings.

CORVETTE

The Corvette rear axle
is of the
type where
the dif-
ferential carrier housing enclosing
the
differential
and

hypoid gears
is
supported
on a
crossmember mounted
to

the chassis frame.
The
differential
is
connected through

universal joints
to the
drive shafts
and
wheels
(fig. 73).

The internal components
of the
carrier
are of
conven-

tional design, incorporating
a
hypoid gear
set
with
an

overhung pinion supported
on two
pre-loaded, tapered

roller bearing assemblies,
and a
two-pinion differential

assembly supported
on
tapered roller bearings. Pinion

mounting distance adjustments
are
made through the
use

of shims,
as are the
differential bearing pre-load
and

backlash adjustments.
The
differential side gears drive

two splined yokes which
are
retained laterally
by
snap

rings located on the yoke splined end. The yokes
are
sup-

ported on caged needle bearings pressed into
the
carrier,

adjacent
to the
differential bearings.
A
lip seal, pressed

in outboard
of
the bearings, prevents
oil
leakage and dirt

entry.
The
carrier cover
is
bolted
to the
carrier and

provides accessibility
to the
internal parts.
The
cover

incorporates two integral, reinforced mounting pads which

serve
as the
carrier attaching point
to the
suspension

crossmember,
and an
attaching point
for the
spring

center section. The filler plug
is
located on the right side

of the cover near the bolting flange.

All service operations allow carrier removal without

removing
the
carrier cover. Cover removal
is
not nec-

essary
in any of the
service procedures except
in
the

case
of
complete carrier housing replacement,
as the

carrier and cover
are
serviced
as
an assembly.

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-29

REAR AXLE NOISE DIAGNOSIS

Mechanical failures of the rear axle are relatively

simple to locate and correct. Noise in a rear axle is a

little more difficult to diagnose and repair. One of the

most essential parts of rear axle service is proper

diagnosis.

Ail rear axles are noisy to a certain degree. The

action of transmitting the high engine torque through a

90° turn reducing propeller shaft speed produces noise

in rear axles. This point establishes the need for a line

between normal and abnormal or unacceptable axle

noises.

Slight axle noise heard only at a certain speed or under

remote conditions must be considered normal. Axle noise

tends to "peak" at varying speeds and the noise is in no

way indicative of trouble in the axle.

If noise is present in an objectionable form, loud or at

all speeds, an effort should be made to isolate the noise

as being in one particular unit of the vehicle. Axle noise

is often confused with other noises such as tire noise,

transmission noise, propeller shaft vibration and uni-

versal joint noise. Isolation of the noise as in any one

unit requires skill and experience. An attempt to elimini-

ate a slight noise may baffle even the best of diagnos-

ticians. Such practices as raising tire pressure to

eliminate tire noise, listening for the noise at varying

speeds and on drive, float and coast, and under proper

highway conditions, turning the steering wheel from left

to right to detect wheel bearing noise, will aid even the

beginner in detecting alleged axle noises. Axle noises

fall into two categories: gear noise and bearing noise.

GEAR NOISE

Abnormal gear noise can be recognized since it pro-

duces a cycling pitch and will be very pronounced in the

speed range at which it occurs, appearing under either

"drive," "float" or "coast" conditions. Gear noise

tends to peak in a narrow speed range or ranges, while

bearing noise will tend to remain constant in pitch. Ab-

normal gear noise is rare and usually originates from

the scoring of the ring gear and pinion teeth as a result

of insufficient or improper lubrication in new assemblies.

Side gears seldom give trouble as they are used only

when the rear wheels travel at different speeds.

BEARING NOISE

Defective bearings will always produce a whine that is

constant in pitch and varies with vehicle speed. This fact

will allow you to distinguish between bearing noise and

gear noise.

1.
Pinion bearing noise resulting from a bearing failure

can be identified by a constant rough sound. Pinion

bearings are rotating at a higher speed than differen-

tial side bearings or axle shaft bearings. This

particular noise can be picked up best by testing the

car on a smooth road (black top). However, care

should be taken not to confuse tire noise with bear-

ing or gear noise. If any doubt exists, tire treads

should be examined for irregularities that would

produce such noise.

2.
Wheel bearing noise may be confused with rear axle

noise. To differentiate between wheel bearings and

rear axle, drive the vehicle on a smooth road at

medium-low speed. With traffic permitting, turn
Fig.
74—Scored Hypoid Ring Gear

the vehicle sharply right and left. If noise is caused

by wheel bearings, it will increase in the turns be-

cause of the side loading. If noise cannot be isolated

to front or rear wheel bearings, inspection will be

necessary.

3.
Side bearings will produce a constant rough noise of

a slower nature than pinion bearings. Side bearing

noise will not fluctuate in the above wheel bearing

test.

Failure Analysis

The most common types of rear axle failures are

hypoid gear tooth scoring and fracture, differential gear

fracture. and/or differential bearing failure, and axle

shaft bearing failure.

Fig.
75-Cracked Hypoid Ring Gear

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-34

COMPONENT PARTS REPLACEMENT (CORVETTE)

AXLE DRIVESHAFT-FIGURE 88

Removal

1.
Disconnect inboard driveshaft trunnion from side

gear yoke.

2.
Bend bolt lock tabs down and remove four bolts

securing shaft flange to spindle drive flange.

3.
Pry driveshaft out of outboard drive flange pilot

and remove by withdrawing outboard end first (fig.

89).

Repairs

1.
Remove bearing lock ring from trunnion yoke.

2.
Support turnnion yoke on a piece of 1-1/4" pipe on

arbor press bed.

3.
Using suitable socket or rod, press trunnion down

far enough to drive opposite bearing cup from yoke.

4.
Remove trunnion and press other bearing cup from

yoke, being careful not to
drop'
cup
or lose bearing

rollers.

5. Remove trunnion and yoke from other joint in a

similar manner.

3

AXLE
II 1

i

c

DRI\

c

y
'E SHAFT ^

AXLE
v

DRIVE^
SHAFT
•
Fig.
88—Axle Driveshaft
6. Remove dust seals from trunnion, clean and inspect

bearing rollers and trunnion. Relubricate bearings

with a high-melting point wheel bearing type

lubricant.

NOTE:
In addition to packing the bearings,

make sure that the lubricant reservoir at the

end of each trunnion is completely filled with

lubricant. In filling these reservoirs, pack lu-

bricant into the hole so as to fill from the .

bottom. This will prevent air pockets and en-

sure an adequate supply of lubricant.

7. Place new dust seals on trunnion, cavity of seal

toward end of trunnion - then position Tool J-21556

over end of trunnion and into cavity portion of seal.

Press seal onto trunnion until tool bottoms against

trunnion (fig. 90).

NOTE:
Installation of seal is critical to proper

sealing - use specified tool during installation

to prevent seal distortion and to assure proper

seating of seal on trunnion.

8. Partially install one bearing cup into yoke. Place

trunnion in yoke and into bearing cup. Install other

bearing cup and press both bearing cups into yoke,

being careful to keep trunnion aligned in bearing

cups.

9. Press bearing cups far enough to install lock rings,

and install lock rings.

NOTE:
It may be more convenient, if neces-

sary, to use a bench vise for removal and

installation, instead of an arbor press. In this

case, proceed with disassembly and assembly

procedure as with an arbor press.

Installation

1.
Place driveshaft inboard trunnion into side gear

yokes and assemble
"XJ"
bolts. Rotate yokes so that

trunnion seats are phased 90° apart.

2.
Install outboard drive flange into spindle drive flange

pilot, position bolt lock over bolt holes and install

four bolts. Torque bolts to specification and bend

lock tabs flat against bolt heads.

Fig. 89—Removing Driveshaft

Fig.
90—
"U"
Joint Trunnion Seal Installation

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-37

9. Connect spring end link bolts as outlined under

Spring--Installation, in this section.

10.
Remove filler plug, located on right side of cover,

and fill -with hypoid lubricant to level of filler hole.

11.
Lower vehicle and road test for leaks, noise and

general performance.

POSITRACTION DIFFERENTIAL UNIT

The optionally available Positraction differential unit

is installed in the conventional carrier to replace the

standard differential unit.

Service procedures for the Positraction equipped axle

are the same as on a conventional axle except for the.

operations listed below.

On the Vehicle Check

If vehicle is equipped with a manual transmission, shift

transmission into neutral.

1.
Raise rear of vehicle until wheels are off the ground,

remove one wheel and tire assembly.

2.
Attach Adapter J-5748 to axle shaft flange and install

a
1/2-13
bolt into adapter (fig. 97).

3.
With wheel and tire assembly still on vehicle held

firmly to prevent turning, measure torque required
Fig.
97—Measuring Positraction Rotating Torque

to rotate opposite axle shaft with a 0-150# torque

wrench attached to J-5748. Torque should be 70

ft.
lbs. minimum new, and no less than 40 ft. lbs. if

used.

PROPELLER SHAFT AND UNIVERSAL JOINTS

INDEX

Page
Page

General Description 4-37

Component Parts Replacement. 4-38

Propeller Shaft (Dana) 4-38

Removal 4-38

Repairs 4-38
Installation 4-39

Propeller Shaft (Saginaw) 4-40

Removal 4-40

Repairs 4-40

Installation 4-41

GENERAL DESCRIPTION

The one-piece, exposed-type, tubular propeller shaft is

used on all models. The cardon-type universal joints are

of the extended-life design and do not require periodic

maintenance. A splined front yoke on the front end of the

propeller shaft extends into a splined coupling on the

transmission output shaft. This slip joint permits slight

lengthening and shortening of the propeller shaft to com-

pensate for up and down movement of the rear axle
assembly.

A light duty (fig. 98) and a heavy duty (fig. 99) version

of the tubular propeller shaft is used. The heavy-duty

shaft incorporates a damper, as part of the sleeve yoke,

at the transmission end of the shaft. This damper is not

serviced separately—the sleeve and damper (fig. 100)

must be replaced as an assembly.

Two different methods are used to retain the trunnions

Fig.
98—Light-Duty Propeller Shaft Cross-Section (Dana Design)

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION
AND
DRIVE LINE
4-38

•"•f •--..—-.>•,«.-. ^

Fig. 99—Heavy-Duty Propeller Shaft Cross-Section

(Saginaw Design)'

in
the
propeller shaft yokes. Conventional snap rings are

used
as
one method—these units can be disassembled and

reassembled using
the
same trunnions
if
desired.
How-

ever, the alternate method
of
retaining the trunnions does

not permit reusing
the
trunnions once they have been
pressed from the yokes. These trunnions are retained by

nylon material which
is
injected through
a
small hole
in

the yoke and into
the
annular grooves between the trun-

nion and yoke.

COMPONENT PARTS REPLACEMENT

PROPELLER SHAFT (DANA)

Removal

1.
Raise vehicle, mark relationship
of
shaft
to com-

panion flange and disconnect the rear universal joint

by removing trunnion bearing "U" bolts
(fig. 101).

Tape bearing cups
to
trunnion
to
prevent dropping

and loss of bearing rollers.

NOTE:
On
Corvette models, remove trunnion

"U"
bolts at transmission yoke also.

2.
Withdraw propeller shaft front yoke from transmis-

sion
by
moving shaft rearward, passing
it
under the

axle housing. Watch
for oil
leakage from transmis-

sion output shaft housing.

Repairs

NOTE:
The
universal joints
(fig. 102) are of
Fig.
101—
Removing Propeller Shaft from Companion Flange

the extended-life design
and do not
require

periodic inspection or lubrication; however, when

Fig.
100—Propeller Shaft Sleeve
and
Damper Assembly
Fig. 102—Propeller Shaft Trunnion (Dana Design)

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-39

Fig.
103—Removing Bearing Caps

these joints are disassembled, repack bearings

and lubricate reservoir at end of trunnions with

high-melting point wheel bearing lubricant and

replace the dust seals.

1.
Remove bearing lock rings from trunnion yoke.

2.
Support trunnion yoke on a piece of 1-1/4" I.D. pipe

on an arbor bed.

NOTE:
Due to length of the propeller shaft it

may be more convenient to use a bench vise,

for removal and installation, instead of an arbor

press.
In this case, proceed with disassembly

and assembly procedure as with an arbor press.

3.
Using a suitable socket or rod, press trunnion down

far enough to drive bearing cup from yoke (fig. 103).

4.
Remove dust seals from trunnion, clean and inspect

bearing rollers and trunnion. Relubricate bearings

with a lithium base chassis lubricant.

NOTE:
In addition to packing the bearings,

make sure that the lubricant reservoir at the

end of each trunnion is completely filled with

lubricant. In filling these reservoirs, pack lu-

bricant into the hole so as to fill from the

bottom. This will prevent air pockets and ensure

an adequate supply of lubricant.

5. Place new dust seals on trunnions - cavity of seal

toward end of trunnion - then position Tool J-21548
over end of trunnion and into cavity portion of seal.

Press seal onto trunnion until tool bottoms against

trunnion (fig. 104). .

NOTE:
Installation of seal is critical to proper

sealing - use specified tool during installation to

prevent seal distortion and to assure proper

seating of seal on trunnion.

6. Partially install one bearing cup into yoke. Place

trunnion in yoke and into bearing cup. Install other

bearing cup and press both bearing cups into yoke

(fig. 105) being careful to keep trunnion aligned in

bearing cups.

7. Press bearing cups far enough to install lock rings,

and install lock rings.

Installation

1.
Inspect yoke seal in the transmission and replace, if

necessary, as described in the transmission section.

2.
Insert propeller shaft front yoke into transmission.

NOTE:
On Corvette models, install front yoke

into transmission then position propeller shaft

between yoke and companion flange; install "U"

bolts to front yoke.

3.
Align propeller shaft with companion flange, using

reference marks established in "Removal" pro-

cedure, connect the rear universal joint by installing

"U"
bolt clamps over bearing trunnions - torque

nuts to specifications.

Fig.
104—"U" Joint Trunnion Seal installation
Fig.
105—Installing Bearing Cup and Trunnion

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-40

Fig.
106—Removing Propeller Shaft from Companion Flange

PROPELLER SHAFT (SAGINAW)

Removal

1.
Raise vehicle sufficiently to permit access to propel-

ler shaft and mark relationship of rear yoke to

companion flange.

2.
Remove trunnion bearing retaining strap attaching

screws from both bearings (fig. 106).

3.
Lower rear of propeller shaft, being careful not to

dislodge bearing caps from trunnion, and tape bear-

ing caps to trunnion.

4.
Withdraw propeller shaft front yoke from transmis-

.sion by moving shaft rearward, passing it under the

axle housing. Watch for oil leakage from transmis-

sion output shaft housing.

Repairs

NOTE:
Because of the elastic properties of the

nylon retainers, the trunnions must be pressed

from the yokes. Pressing the trunnions from the

yokes will shear the retainers which renders

the bearing caps unsuitable for reuse. A service

Jdt, which employs a snap ring to retain the

trunnion, must be used when reassembling the

propeller shaft (fig. 107).

1.
Remove trunnion at differential end of propeller shaft

Fig.
107—Service Kir Trunnion (Saginaw)
Fig.
108—Pressing Trunnion Bearing from Propeller Shaft

using the following procedure:

a. Support trunnion on a press bed so that the

propeller shaft yoke can be moved downward.

Support front of propeller shaft so that shaft is

in a horizontal position.

b.
Using a piece of pipe or similar tool, with an ins-

side diameter slightly larger than 1 1/8", press

bearing from yoke (fig. 108).

c. Apply force on yoke around bearing until nylon

retainer breaks. Continue to apply force until the

downward movement of the yoke forces the bear-

ing as far as possible from the yoke (fig. 109).

d. Complete removal of bearing by tapping around

circumference of exposed portion with a small

hammer (fig. 110).

e. Rotate propeller shaft so that opposite bearing

-may be removed in the manner described above.

f. Remove trunnion from yoke.

Remove trunnion at transmission end of propeller

shaft using the following procedure:

a. Support splined yoke on a press bed and the rear

of the propeller shaft on a stand so that shaft is

horizontal. Be sure that weight is evenly dis-

tributed on each side of the splined yoke and that

the fixed yoke half of the "U" joint is free to

move downward.

b.
Using a piece of pipe or similar tool, with an

inside diameter slightly larger than 1 1/8", press

bearing from yoke (fig. 108).

c. Apply force on yoke around bearing until nylon

retainer breaks. Continue to apply force until the

downward movement of the yoke forces the bear-

ing as far as possible from the yoke (fig. 109).

d. Complete removal of bearing by tapping around

circumference of exposed portion with a small

hammer (fig. 110).

e. Rotate propeller shaft so that opposite bearing

may be removed in the manner described above.

f. Remove splined yoke and trunnion from propeller

shaft.

CHEVROLET CHASSIS SERVICE MANUAL