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HOMESERVICE MANUALSCHEVROLET1986CAVALIER RS, 2D HATCHBACK, 2.8 W, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSOVERHAUL & TESTING - 125C/3T40COMPONENT DISASSEMBLY & REASSEMBLYDIFFERENTIAL & FINAL DRIVEREASSEMBLY
1986 Chevrolet Cavalier RS, 2D Hatchback, 2.8 W, Automatic

Differential & Final Drive: Reassembly

1986 Chevrolet Cavalier RS, 2D Hatchback, 2.8 W, AutomaticSECTION Reassembly
  1. If governor drive gear is removed, lightly tap it into place with a plastic mallet. Install needle bearings. Install steel pinion thrust washer onto end of pin (side opposite first thrust washer). Install one bronze pinion thrust washer to each end of pin. Slide pinion pin from assembly, keeping bearings intact in gear.
  2. Install pinion gear assembly into final drive carrier. Install pinion pin (stepped end last) into carrier through pinion gear assembly. Install other final drive pinion gears using same procedure. Install spiral pinion pin snap ring.
  3. Install pinion pin so step is outside. Ensure bronze thrust washer is present on each end of final drive pinion, between carrier and steel thrust washer.
  4. Install internal gear thrust bearing, sun gear with stepped side facing upward, thrust bearing with outside race to internal gear, and internal gear into final drive internal carrier. Install differential side gear thrust washers and side gears. Hold them in place with petroleum jelly. Coat side gear pinion dished thrust washers with petroleum jelly, and install them onto side gear pinions. Install pinion gears in differential carrier windows.
  5. Install differential carrier case selective thrust washer into differential carrier case. Install thrust bearing into carrier assembly. Use petroleum jelly to hold bearing in place. Using Final Drive Unit Remover/Installer (J-33381), install differential carrier assembly into final drive internal case.
  6. Install final drive internal gear spacer into case. Ensure parking pawl moves freely after spacer installation. Install snap ring into groove. Ensure final drive-to-case end play is .005-.032" (.12-.81 mm). See FINAL DRIVE UNIT  under TRANSAXLE DISASSEMBLY. See Fig 1 .
Fig 1: Checking Final Drive End Play
G92J12681Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.