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HOMESERVICE MANUALSCHEVROLET1990STEP VAN 6.2 J, AUTOMATIC, 3L80-HD/M40REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 13 (DRIVE AXLE - FRONT)OVERHAULAXLE CARRIERREASSEMBLY
1990 Chevrolet Step Van 6.2 J, Automatic, 3L80-HD/M40

Axle Carrier: Reassembly

1990 Chevrolet Step Van 6.2 J, Automatic, 3L80-HD/M40SECTION Reassembly
WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 1990 GMC Pickup, 1990 GMC Cab & Chassis, 1990 Chevrolet Pickup, 1990 Chevrolet Cab & Chassis, and 1989 GMC Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate outer pinion and inner bearing races. Install Holding Fixture from Pinion Service Set (J-36598) used during disassembly. Using race installer from kit, press and pull in outer and inner races until races are seated in housing. Lubricate the inner and the outer bearings, then set pinion depth. Refer to DRIVE PINION DEPTH ADJUSTMENT .
  2. Install proper shim selected during pinion depth adjustment and inner pinion bearing on pinion shaft using Pinion Bearing Installer (J-35512) for K10/20 Series or (J-36614) for K30 Series. Install new collapsible spacer on pinion shaft. Lubricate outer pinion bearing and install bearing and pinion seal into carrier. Insert pinion with inner bearing and spacer into carrier.
  3. Install deflector, pinion flange, washer and nut. Install flange holder used when removing flange and hold flange while torquing pinion flange nut. Torque nut until no end play is present. DO NOT  torque further.
  4. Rotate pinion several times to ensure bearings have been seated. Set final preload to 15-25 INCH lbs. (1.7-2.8 N.m) by torquing pinion nut in small increments. Each tightening increases preload by several INCH pounds.
  5. If preload specification is exceeded, pinion must be removed and collapsible spacer replaced. Once preload has been obtained, rotate pinion several times to ensure bearings have seated and recheck preload. Readjust if necessary.
  6. Install side gears and thrust washers into differential case. On K30 Series, install side gear spacer on left-hand side. If old side gears are being reinstalled, ensure they are placed in their original locations as marked during disassembly.
  7. Position one pinion gear between side gears and rotate gears until pinion gear is directly opposite opening in case. Place remaining pinion gear between side gears, making sure holes in both pinion gears line up. Rotate pinion gears toward opening just enough to allow installation of thrust washers.
  8. Install differential pinion gear shaft. Install roll pin through case and into pinion gear shaft. On K30 Series, install pinion gear shaft bolt (if equipped). Install ring gear onto differential assembly. Torque new bolts alternately in progressive steps to 88 ft. lbs. (120 N.m). Ring gear uses left-hand thread bolts.
  9. Press side bearings onto differential assembly using Adapter (J-8092) and Side Bearing Installer (J-22761) for K10/20 Series or (J-29710) for K30 Series. Press bearings onto sleeves (and adjuster plug on left side of K30 Series) using Adapter (J-8092) and Bearing Installer (J-36612) for K10/20 Series or (J-36613) for K30 Series.
  10. On K30 Series, install new "O" ring to adjuster plug. Using sleeve adjusting wrench used during disassembly, install sleeves into carrier case (except left side on K30 Series). On left side of carrier on K30 Series, install adjuster plug using same adjuster plug wrench used during disassembly.
  11. Install side bearing races into carrier using Adapter (J-8092) and Race Installer (J-36603). Place differential assembly into left carrier case half. Turn left sleeve (K10/20 Series) or left adjuster plug (K30 Series) inward until backlash is felt between the ring and pinion.
  12. Remove carrier case from holding fixture and attach carrier halves together using 4 bolts. If halves do not make complete contact, back out right sleeve. Install carrier case bolts and torque to 35 ft. lbs. (47 N.m). Set ring gear backlash adjustment to specification. See RING GEAR BACKLASH ADJUSTMENT .
  13. Bend lock tabs over left (K10/20 Series only) and right sleeves. On K30 Series, install left adjuster plug lock and bolt. Remove 4 bolts holding axle carrier halves together and separate housing halves. Apply Loctite (518) or appropriate sealant to one carrier housing surface.
  14. Reconnect axle carrier housing halves. Install 10 attaching bolts and torque to specification. Using appropriate seal installer, install seal into left side of carrier case. Place deflector onto left output shaft and insert into left side of carrier. Drive into place with a soft-faced hammer.
  15. Install new pilot bearing into right output shaft using Pilot Bearing Installer (J-33842). Insert right output shaft into right side of carrier. Apply Loctite (518) or appropriate sealant to threads of vent plug. Install vent plug into left side of carrier.
  16. Install right axle tube and inner shaft assembly. See RIGHT AXLE TUBE & INNER SHAFT  under REMOVAL & INSTALLATION.
RENDER: 1.0x

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  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
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