CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
Page 221 of 659
REAR SUSPENSION AND DRIVE LINE 4-31
Fig.
77—Differential Pinion Shaft Removal
AXLE SHAFT
Removal
1.
Raise vehicle to desired working height and remove
wheel and tire assembly and brake drum.
2.
Clean all dirt from area of carrier cover. *
3.
Drain lubricant from carrier by removing cover.
4.
Remove the differential pinion shaft lock screw and
the differential pinion shaft (fig. 77).
5. Push flanged end of axle shaft toward center of
vehicle and remove "C" lock from button end of
shaft.
6. Remove axle shaft from housing, being careful not
to damage oil seal.
Wheel Bolt Replacement .
Press bolts out of axle shaft flange (as illustrated in
Figure 78) and press new bolts into place, making sure
that they are tight and square with flange.
Off Seal and/or Bearing Replacement
•1.
Remove the oil seal by using the button end of the
axle shaft - insert the button end of the shaft behind
the steel case of the oil seal, then pry seal out of
bore being careful not to damage housing.
2.
Insert Tool J-8119 into bore and position it behind
bearing so that tangs on tool engage bearing outer
x race. Remove bearing, using slide hammer as shown
in Figure 79. Figure 80 shows a detail of axle
housing outer end.
3.
Lubricate new bearing with wheel bearing lubricant,
and install bearing so that it bottoms against
Fig.
79—Wheel Bearing Removal
shoulder (fig. 81). To install bearing use Tool
J-21491 for the Chevelle, Camaro and Chevy JI
light-duty axle and Tool J-21051 for all Chevrolet
models and also for Chevelle, Camaro and Chevy tl
models with heavy-duty axle.
Pack cavity between the seal lips with a high melting
point wheel bearing lubricant; position seal on tool
(Use J-21491 for the Chevelle, Camaro and Chevy II
light-duty axle and J-21051 for all Chevrolet models
and also for Chevelle, Camaro and Chevy II models
with heavy-duty axle) and position seal in axle
housing bore, tap seal into place so that it bottoms
against bearing (fig. 81).
Brake Flange Plate Replacement
1.
Remove "brake line at wheel cylinder inlet and dis-
assemble brake components from flange plate. Refer
to Section 5 for brake disassembly procedure.
2.
Remove 4 nuts securing flange plate to axle housing.
3.
Install new flange plate to axle housing and torque
nuts to specifications.
Fig.
78—Wheel Bolt Replacement
Fig.
80-Axle Housing Detail
CHEVROLET CHASSIS SERVICE MANUAL
Page 222 of 659
REAR SUSPENSION AND DRIVE LINE 4-32
HP?
Fig.
81
—Whed Bearing and/or Oil Seal Installation
4.
Install brake components on flange and connect
hydraulic line to wheel cylinder inlet. See Section 5
for brake assembly procedure.
5. Install axle shaft, brake drum and wheel and tire
assembly.
6. Bleed and. adjust brakes as outlined in Section 5.
Installation
1.
Slide axle shaft into place.
CAUTION: Exercise care that splines on end
of shaft do not damage oil seal and that they
engage with splines of differential side gear/
2.
Install axle shaft "C" lock on button end of axle-
shaft and push shaft outward so that shaft lock seats
in counterbore of differential side gear.
3.
Position differential pinion shaft through case and
pinions, aligning hole in shaft with lock screw hole.
Install lock screw and torque to specifications.
4.
Using a new gasket, install carrier cover and torque
bolts to specifications.
CAUTION: Make sure both gasket surfaces on
carrier and cover are clean before installing
new gasket. Torque carrier cover bolts in a
crosswise pattern to ensure uniform draw on
cover gasket.
5. Fill axle with lubricant to a level even with bottom
of filler hole. See Section 0 for proper lubricant.
6. Install brake drum and wheel and tire assembly.
7. Lower vehicle and test operation of axle.
PINION FLANGE, DUST DEFLECTOR
AND/OR OIL SEAL
Replacement
1.
Raise rear of vehicle and place stand jacks under
frame side rails so that axle hangs freely to allow
sufficient working room.
2.
Check wheels for freedom of rotation.
3.
Separate rear universal joint, tape trunnion bearings
to joint, position propeller shaft to one side and tie
it to frame side rail.
4.
Using Tool J-5853 with Adapter J-5810 and a suitable
socket on the pinion flange nut, rotate the pinion
through several complete revolutions and record the
torque required to keep the pinion turning (fig. 82).
If flange is to be reused, mark pinion and flange for
reassembly in the same relative position.
5. Install Tool J-8614-1 on pinion flange and remove
pinion flange nut and washer (fig. 83). (Position
Fig. 82—Measuring Drive Pinion Bearing Preload
J-8614-1 on flange so that the four notches are
toward flange.) Discard nut and use a new one
upon reassembly.
6. Thread pilot end of Tool J-8614-3 into small O.D.
end of J-8614-2. Then with J-8614-1 installed as
in Step 4, insert J-8614-2 into J-8614-1 and turn
it 45 degrees to locked position. Remove flange by
turning J-8614-3 while holding J-8614-1 (fig. 84).
7. Pry old seal out of bore, using a screw driver or a
hammer and chisel.
8. Inspect pinion flange for smooth oil seal surface,
worn drive splines, damaged ears, and for smooth-
ness of bearing contact surface. Replace if
necessary.
9. If deflector requires replacement, remove by tapping
from flange, clean up stake points; install new de-
flector, and stake deflector at three new equally
spaced positions.
NOTE:
Staking operation must be performed
in such a manner that the seal operating surface
is not damaged.
1.0. Pack the cavity between the seal lips of the pinion
flange oil seal with a lithium-base extreme pressure
lubricant, position seal in bore, then using Tools
J-21468 and J-9458, for light-duty axle and Tool
Fig. 83-—Drive Pinion Nut Removal
CHEVROLET CHASSIS SERVICE MANUAL
Page 223 of 659
REAR SUSPENSION AND DRIVE LINE 4-33
Fig.
84—Drive Pinion Flange Removal
J-21057 for heavy-duty axle, press seal into bore
until it seats against shoulder (figs. 85 and 86).
CAUTION: Pinion oil seal flange must not bot-
tom against "carrier. Press seal into carrier
bore until it seats against internal shoulder -
do not apply unnecessary pressure after seal is
seated. To do so will destroy rubber seat ancl
distort seal. ;
11.
Position and align pinion flange on pinion shaft using
Tools J-9458 and
J-8614-1.
Tool J-9458-1 is
threaded onto pinion shaft and nut tightened against
J-9458-2 to pull flange on shaft (fig. 87). Remove
Fig.
86—Drive Pinion Flange Oil Seal
Installation (Heavy-Duty)
J-9458 after flange is seated.
NOTE: The position of the pinion and flange
was previously marked so that reinstallation
may be made with flange and pinion in same
relative position.
CAUTION: Do not attempt to hammer flange
onto pinion shaft. To do so will damage ring
gear and pinion.
12.
13.
14.
15.
Pack the cavity between end of pinion splines and
pinion flange with a non-hardening sealer (such as
Permatex Type A) prior to installing washer and
nut on pinion.
Install washer and a new self-locking nut on pinion
shaft. Tighten nut to remove end play and continue
alternately tightening in small increments and check-
ing preload with torque wrench until it is the same
as that recorded in Step 4.
Reassemble the rear universal joint, and torque
"V" bolt nuts to specifications.
Lower vehicle to floor and road test for leaks.
Fig.
85—Drive Pinion Flange Oil Seal
Installation (Light-Duty)
Fig.
87—Drive Pinion Flange Installation
CHEVROLET CHASSIS SERVICE MANUAL
Page 224 of 659
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
•<i-^""^
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
Page 225 of 659
REAR SUSPENSION AND DRIVE LINE 4-35
Fig.
91—
Removing Carrier Front Support
PINION FLANGE, DUST DEFLECTOR
AND/OR OIL SEAL
Removal
1.
Raise vehicle and place jackstand under frame to
allow wheels to hang free.
2.
Place 1/2" thick block of wood or steel between
carrier upper surface to rear of companion flange,
and body floor. This will prevent carrier assembly
from twisting upward when front support bracket is
disconnected.
3.
Disconnect carrier front mounting bracket bolt from
frame crossmember.
4.
Remove nut from carrier bracket front bolt and
slide bolt to one side until bolt head contacts floor
well. Mark the floor well at this point and drill a
3/4"
diameter hole - remove bolt.
5. Loosen bracket rear bolt and swing bracket down
and to the rear (fig. 91).
6. Disconnect propeller shaft at transmission and at
companion flange. Slide transmission yoke forward,
and lower propeller shaft down and out.
7. Mark companion flange nut and pinion relative loca-
tion.
This is necessary to reset original pinion
bearing pre-load during reassembly of companion
flange.
8. Attach J-8614-1 companion flange holder and remove
flange nut and washer (fig. 92).
9. Remove companion flange by driving off with brass
drift and hammer (fig. 93).
10.
Using screw driver, pry oil seal out of carrier.
Inspection
Inspect companion flange splines for excessive wear
or twisting and check deflector for looseness. If de-
flector is loose or damaged, break stake marks and
remove. Install new deflector and stake in place.
Installation
1.
Place sealing compound around O.D. of new seal
and install seal in carrier using seal Installer
J-21057 (fig. 94).
Fig.
92—Removing Companion Flange Nut
NOTE:
Seal should be started squarely in bore
to eliminate seal distortion.
2.
Tap seal into position until there is a 1/8" gap be-
tween seal flange and carrier (fig. 95).
3.
Lubricate companion flange splines and tap into
place.
4.
Install companion flange washer and nut, and tighten
nut so that it lines up with mark on pinion.
5. Raise propeller shaft into position and connect to
companion flange and transmission yoke.
6. Place rubber cushion on carrier front mounting
bracket and raise bracket into position and loosely
install nut.
7. Install carrier bracket front bolt. With vehicle at
curb,
torque all affected parts to specifications and
install cotter pin to carrier bracket front bolt.
8. Insert a plastic plug from the inside of the floor
well to prevent dust and water entry.
Fig.
93—Removing Companion Flange
CHEVROLET CHASSIS SERVICE MANUAL
Page 226 of 659
REAR SUSPENSION AND DRIVE LINE 4-36
Fig.
94—Installing Pinion Oil Seal
DIFFERENTIAL CARRIER
Removal
1.
Disconnect spring end link bolts as outlined in
Spring—Removal, in this section.
2.
Disconnect axle drive shafts at carrier by removing
"U"
bolts securing trunnion to side gear yoke.
3.
Disconnect carrier front support bracket at frame
crossmember.
4.
Disconnect propeller shaft at transmission and at
companion flange. Slide transmission yoke forward
into transmission. Drop propeller shaft down and
Fig.
95-Pinion Sea! Installed
out toward the rear.
5. Mark camber cam and bolt relative location on strut
rod bracket and loosen cam bolts.
6. Remove four bolts securing bracket to carrier lower
surface and drop bracket. Remove camber cam bolts
and swing strut rods up and out of the way.
7. Remove eight carrier-to-cover bolts. Loosen bolts
gradually to allow lubricant to drain out.
8. With mounting bolts removed, pull carrier partially
out of cover, drop nose to clear crossmember and
gradually work carrier down and out.
Installation
1.
Clean inside of carrier cover and liberally grease
gasket surface. Place new gasket on cover.
2.
Cut heads off two l/2"-13 x 1-1/4" bolts and slot
unthreaded end. Install these aligning studs into two
below-center carrier bolt holes, one on each side.
3.
Raise carrier into position aligning studs into
cover (fig. 96).
4.
Install carrier-to-cover bolts and tighten securely.
5. Connect propeller shaft to companion flange and
transmission yoke.
6. Install rubber cushion on bracket and position to
frame crossmember. Install hut and torque to
specifications.
7. Raise axle drive shafts into position and assemble
inboard trunnion to side gear yokes with "U" bolts.
8. Assemble strut rods to bracket and raise bracket
into position under carrier. Install four bolts and
torque to specifications. Move camber cams to
marked location and tighten cam nuts.
Fig.
96—Installing Carrier Assembly
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Page 227 of 659
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
Page 228 of 659
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
Page 229 of 659
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
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Page 230 of 659
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