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HOMESERVICE MANUALSCHEVROLET1993SPORTVAN G30, VAN PASSENGER, 7.4 NREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 38 (DRIVE AXLE - FRONT)OVERHAULRIGHT AXLE TUBE ASSEMBLYREASSEMBLY
1993 Chevrolet Sportvan G30, Van Passenger, 7.4 N

Right Axle Tube Assembly: Reassembly

1993 Chevrolet Sportvan G30, Van Passenger, 7.4 NSECTION Reassembly
WARNING: This page does not describe the selected car, but rather 16 other vehicles, including the 1994 GMC Yukon, 1994 GMC Suburban, 1994 GMC Pickup, 1994 GMC Cab & Chassis, and 1994 Chevrolet Suburban. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean gasket surfaces on axle tube and carrier housing. Lubricate NEW bearing using wheel bearing grease. Using Bearing Installer (J-36609 ), install axle bearing into tube. Lightly coat lip of NEW seal with grease. Install seal using Seal Installer (J-36600 for K15/25 or J-22833 for K35).
  2. Install deflector to axle shaft (if removed) and insert axle shaft into axle tube. Install thrust washer, ensuring tube slots align with tabs on washer. See Fig 1. Use wheel bearing grease to hold thrust washer in place.
    Fig 1: Installing Axle Tube Thrust Washer
    G90J15239Courtesy of GENERAL MOTORS CORP.
  3. On K15/25, drive connector gear onto end of axle, using a plastic hammer. Install snap ring. On K35, install washer and snap ring. Ensure snap ring seats properly in groove. On all models, an output shaft shim (No. 20) of proper thickness must be selected if any of following parts have been changed.
    • Differential Case
    • Inner Shaft
    • Connector Gear (K15/25)
    • Axle Tube
    • Output Shaft
    • Carrier Case
    • Ring and Pinion
    • Bearings

    If no parts have been changed, go to step 6).

  4. If any of listed parts have been changed, use grease to hold ORIGINAL shim in place. Assemble axle tube and inner shaft assembly to carrier. Use no sealer at this time. Tighten bolts to 30 ft. lbs. (41 N.m).
  5. Install dial indicator onto axle tube with dial indicator shaft at right angle to axle output shaft flange. Check axle shaft end play by pushing and pulling in and out on axle shaft. Maximum end play is .001-.020" (.03-.51 mm). If end play is incorrect, select shim as necessary to bring end play within specification. Remove axle tube from carrier.
  6. Ensure axle tube and carrier case sealing surfaces are clean. Install correct shim onto output shaft using wheel bearing grease. Slip damper spring onto shift shaft. Slide shift fork onto shift shaft, ensuring damper spring fits into indentation in shift fork.
  7. Install clip, ensuring clip seats properly in shift shaft groove. Install fork tension spring on shift shaft. Insert shift fork into groove in differential sleeve. Install shift fork assembly into tube assembly at same time installing sleeve onto connector gear (K15/25) or axle shaft splines (K35).
  8. Apply a bead of Sealant (GM 1052942 or Loctite 518 ) to axle tube sealing surface. Assemble axle tube to carrier case. Install axle tube-to-carrier bolts, and tighten bolts to specification. See TORQUE SPECIFICATIONS  table.
  9. Inspect shift mechanism operation by inserting a drift into shift actuator hole on axle tube. Rotate axle shaft flange while moving the shift mechanism back and forth with drift. Shift mechanism should work smoothly without binding.
  10. Apply appropriate sealant (GM 1052942 or Loctite 518 ) to threads of actuator solenoid and install solenoid onto axle tube. Repeat procedure with switch assembly.
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.