1993 CHEVROLET DYNASTY differential

Fig. 3 Differential Cover Bolts
Fig. 4 Remove or Install Differential Cover
Fig. 5 Differential Retainer Bolts
Fig. 6 Remove or Install Bearing Retainer
Fig. 7 Differential Bearing Retainer
Fig. 8 Extension Bolts
Ä TRANSAXLE 21 - 137

Fig. 9 Remove or Install Extension
Fig. 10 Differential and Extension
Fig. 11 Remove Differential Bearing Cone
Fig. 12 Install Differential Bearing Cone
Fig. 13 Remove Differential Bearing Cone
Fig. 14 Install Differential Bearing Cone
21 - 138 TRANSAXLE Ä

CAUTION: Always install NEW ring gear bolts. Bolts
must be properly torqued. CAUTION: Side gear end play must be within .001
to .013 inch.
Fig. 15 Torque New Ring Gear Bolts to 95 NIm (70
ft. lbs.)
Fig. 16 Remove Pinion Shaft Roll Pin
Fig. 17 Remove or Install Pinion Shaft
Fig. 18 Remove or Install Pinion Gears, Side Gears, and Tabbed Thrust Washers, by Rotating Pinion Gears to Opening in Differential Case
Fig. 19 Differential Gears
Fig. 20 Checking Side Gear End Play
Ä TRANSAXLE 21 - 139

Four select thrust washers are available: .032,
.037, .042, and .047 inch.
CAUTION: Side gear end play must be within .001
to .013 inch.
Four select thrust washers are available: .032,
.037, .042, and .047 inch.
DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of
the following parts are replaced:
² Transaxle case
² Differential carrier
² Differential bearing retainer
² Extension housing
² Differential bearing cups and cones
Refer to Bearing Adjustment Procedure in rear
of this section to determine proper shim thickness for
correct bearing preload and proper bearing turning
torque.
Fig. 21 Checking Side Gear End Play
Fig. 22 Remove Oil Seal
Fig. 23 Install New Oil Seal
Fig. 24 Remove Bearing Cup
Fig. 25 Differential Bearing Retainer
21 - 140 TRANSAXLE Ä

When rebuilding, reverse the above procedure.
Remove old sealant before applying new seal-
ant. Use MOPAR tAdhesive Sealant on retainer
to seal retainer to case.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Take extreme care when removing and in stalling
bearing cups and cones. Use only an arbor press for
installation, as a hammer may not properly align the
bearing cup or cone. Burrs or nicks on the bearing seat
will give a false end play reading, while gauging for
proper shims. Improperly seated bearing cup and cones
are subject to low-mileage failure. (2) Bearing cups and cones should be replaced if they
show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers,
both cup and cone must be replaced. Bearing end play and drag torque specifica-
tions must be maintained to avoid premature
bearing failures. Used (original) bearing may lose up to 50
of the original drag torque after break-in.
All bearing adjustments must be made with no
other component interference or gear inter-
mesh, except the transfer gear bearing. Oil all bearings before checking turning torque.OUTPUT GEAR BEARING
With output gear removed:
(1) Install a 4.50 mm (0.177 inch) gauging shim on
the rear carrier assembly hub, using grease to hold the
shim in place. (2) Install output gear and bearing assembly. Torque
to 271 N Im (200 ft. lbs.).
(3) To measure bearing end play:
Fig. 26 Install Bearing Cup
Fig. 27 Checking Differential End Play
Fig. 28 Tool L-4436 and Torque Wrench
Fig. 29 Checking Differential Bearings Turning Torque
Ä TRANSAXLE 21 - 141

(a) Attach Tool L-4432 to the gear.
(b) Push and pull the gear while rotating back
and forth to insure seating of the bearing rollers. (c) Using a dial indicator, mounted to the tran-
saxle case, measure output gear end play.
(4) Once bearing end play has been determined, re-
fer to the output gear bearing shim chart for the re-
quired shim to obtain proper bearing setting. (5) Use Tool 6259 to remove the retaining bolt and
washer. To remove the output gear, use Tool L-4407. (6) Remove the gauging shim and install the
proper shim. Use grease to hold the shim in place.
Install the output gear and bearing assembly.
CAUTION: Always use new retaining bolt, old re-
taining bolt may not be reused.
(7) Install the new retaining bolt and washer.
Tighten to 271 N Im (200 ft. lbs.).
(8) Using an inch-pound torque wrench, check the
turning torque. The torque should be between 3
and 8 inch-pounds. If the turning torque is too high, install a .04 mm
(.0016 inch) thicker shim. If the turning torque is too
low, install a .04 mm (.0016 inch) thinner shim. Re-
peat until the proper turning torque is 3 to 8 inch
pounds.
DIFFERENTIAL BEARING
(1) Remove the bearing cup from the differential
bearing retainer using Tool L-4518, and remove the
existing shim from under the cup. (2) Install a .50 mm (.020 inch) gauging shim and
reinstall the bearing cup into the retainer. Use an
arbor press to install the cup. Oil Baffle is not required when making shim
selection. (3) Install the bearing retainer into the case and
torque bolts to 28 N Im (250 in. lbs.).
(4) Position the transaxle assembly vertically on the
support stand and install Tool C-4995 into side gear. (5) Rotate the differential at least one full revolution
to ensure the tapered roller bearings are fully seated.
(6) Attach a dial indicator to the case and zero the
dial indicator. Place the indicator tip on the end of Tool
L-4436. (7) Place a large screwdriver to each side of the ring
gear and lift. Check the dial indicator for the amount of
end play.
CAUTION: Do not damage the transaxle case and/or
differential cover sealing surface.
OUTPUT GEAR BEARING SHIM CHART
DIFFERENTIAL BEARING SHIM CHART
21 - 142 TRANSAXLE Ä

(8) When the end play has been determined, refer to
the Differential Bearing Shim Chart for the correct
shim combination to obtain the proper bearing setting. (9) Remove the differential bearing retainer. Re-
move the bearing cup and the .50 mm (.020 inch)
gauging shim. (10) Install the proper shim combination under the
bearing cup. Make sure the oil baffle is installed
properly in the bearing retainer, below the bearing
shim and cup. (11) Install the differential bearing retainer. Seal
the retainer to the housing with MOPAR tAdhesive
Sealant and torque bolts to 28 N Im (250 in. lbs.).
(12) Using Tool C-4995 and an inch-pound torque
wrench, check the turning torque of the differential.
The turning torque should be between 5 and 18
inch-pounds. If the turning torque is too high, install a .05
mm (.002 inch) thinner shim. If the turning
torque is too low, install a .05 mm (.002 inch)
thicker shim. Repeat until 5 to 18 inch-pounds
turning torque is obtained.
TRANSFER SHAFT BEARING
(1) Use Tool 6259 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool
L-4407. (2) Install a 4.66 mm (.184 inch) gauging shim on the
transfer shaft. (3) Install transfer shaft gear and bearing assembly
and torque the nut to 271 N Im (200 ft. lbs.).
(4) To measure bearing end play: (a) Attach Tool L-4432 to the transfer gear.
(b) Mount a steel ball with grease into the end of
the transfer shaft. (c) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers. (d) Using a dial indicator, measure transfer shaft
end play.
(5) Refer to the Transfer Bearing Shim Chart for the
required shim combination to obtain the proper bear-
ing setting. (6) Use Tool 6259 to remove the retaining nut and
washer. Remove the transfer shaft gear using Tool
L-4407. (7) Remove the gauging shim and install the correct
shim. Install the transfer gear and bearing assembly.
CAUTION: Original retaining nut may not be re- used. Always use a new retaining nut when reassem-
bling.
(8) Install the new retaining nut and washer and
torque to 271 N Im (200 ft. lbs.). Measure transfer
shaft end play, end play should be .05 to .10 mm
(.002 to .004 inch). (9) Measure bearing end play as outlined in Step (4).
End play should be between .05 mm and .10 mm (.002
to .004 inch). If end play is too high, install a .04 mm (.0016
inch) thinner shim. If end play is too low, install
a .04 mm (.0016 inch) thicker shim combination.
Repeat until .05 to .10 mm (.002 to .004 inch) end
play is obtained.
TRANSFER BEARING SHIM CHART
Ä TRANSAXLE 21 - 143

REFRIGERANT SERVICE PROCEDURES INDEX
page page
Adding Partial Refrigerant Charge ............ 10
Charging Refrigerant SystemÐEmpty System . . . 11
Discharging Refrigerant System .............. 11
Evacuating Refrigerant System .............. 11
Manifold Gauge Set Connections ............. 9 Oil Level
............................... 12
R-12 Refrigerant Equipment ................. 8
Refrigerant Recycling ...................... 9
Sight Glass Refrigerant Level Inspection ........ 8
Testing for Refrigerant Leaks ............... 10
SIGHT GLASS REFRIGERANT LEVEL INSPECTION
The filter-drier is equipped with a sight glass (Fig.
1) that is used as a refrigerant level indicator only.
This sight glass is not to be used for A/C perfor-
mance testing. To check the refrigerant level re-
move the vehicle jack. Then clean the sight glass,
start and warm up engine, and hold rpm slightly
above idle (1100 rpm). Place the air conditioning con-
trol on A/C, RECIRC and high blower. The work
area should be at least 21ÉC (70ÉF). If a Fixed Dis-
placement type compressor does not engage, the re-
frigerant level is probably too low for the Low
Pressure Cut-Off switch to detect. Or, with a Vari-
able Displacement compressor, for the Differential
Pressure Cut-off to detect. If compressor clutch does
not engage, test the refrigerant system for leaks. If
compressor clutch engages, allow approximately one
minute for refrigerant to stabilize. View refrigerant
through sight glass. The suction line should be cold
to the touch and the sight glass should be clear.
If foam or bubbles are visible in sight glass, the re- frigerant level is probably low. Occasional foam or
bubbles are normal when the work area temperature
is above 43ÉC (110ÉF) or below 21ÉC (70ÉF). If suction
line is cold and occasional bubbles are visible in the
sight glass, block the condenser air flow. This will in-
crease the compressor discharge pressure. Do not al-
low engine to over heat. Bubbles should dissipate.
If not, the refrigerant level is low.
CAUTION: Do not allow engine to over heat while
blocking the condenser air flow.
WARNING: R-12 REFRIGERANT IS DETRIMENTAL
TO THE ENVIRONMENT WHEN RELEASED TO THE
ATMOSPHERE. DO NOT ADD R-12 REFRIGERANT
TO A SYSTEM THAT HAS A KNOWN LEAK.
The refrigerant system will not be low on (R-12)
unless there is a leak. Find and repair the leak be-
fore charging.
R-12 REFRIGERANT EQUIPMENT
WARNING: EYE PROTECTION MUST BE USED
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE PROCEEDING WITH THIS OPERATION.
PERSONNEL INJURY CAN RESULT.
When servicing an air conditioning system, an A/C
charging station is recommended (Fig. 2). An (R-12)
refrigerant recovery/recycling device (Fig. 3) should
also be used. This device should meet SAE standards.
Contact an automotive service equipment supplier
for refrigerant recycling/recovering equipment. Refer
to the operating instructions provided with the
equipment for proper operation. A manifold gauge set (Fig. 4) must also be used in
conjunction with the charging and/or recovery/recy-
cling device. The service hoses on the gauge set be-
ing used should have manual (turn wheel) or
automatic back flow valves at the service port con-
nector ends. This will prevent refrigerant from being
release into the atmosphere.
Fig. 1 Filter Drier and Sight Glass
24 - 8 HEATING AND AIR CONDITIONING Ä