Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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The axle housing assembly consists of a cast-aluminum center section, a removable cast-aluminum axle housing tube (3B210), and a differential housing cover (3N136). Both the axle housing tube and the differential housing cover use silicone sealant as a gasket. The hypoid-design gearset consists of an 8.8-inch ring gear (3A397) and a pinion gear (3N175). Two opposed tapered roller bearings support the drive pinion in the axle housing. A drive pinion collapsible spacer (4662), located on the pinion shaft, maintains pinion bearing preload. The pinion nut adjusts the preload. Differential bearing shims (4A451), located between the differential bearing cups (4221) and the axle housing, adjust the differential bearing preload and the ring gear backlash. The differential case (4205) is a one-piece design with two openings to allow for assembly of the internal components and lubricant flow. Two opposed tapered roller bearings (differential bearings [4221]) support the differential case in the axle housing. Removable differential bearing caps (4224) retain the differential assembly in the axle housing. Inside the differential case, the differential pinion shaft (4211) supports two differential pinion gears (4215). The pinion gears engage the differential side gears (4236), to which the left axle shaft (3A381) and the axle cluster gear shaft (7L253) are splined. The differential pinion shaft bolt retains the differential pinion shaft in the differential case. An embossed metal tag, bolted to the rear face of the RH axle tube, contains front axle identification information. CAUTION: Actuate the front drive axle with the wheels in a straight ahead position, and at light throttle only. A front axle actuator motor assembly (7G360), controlled by an instrument panel-mounted switch, actuates the front drive axle.

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REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION DESCRIPTION
Vehicles equipped with 4WD and C205F front axle assembly use equal length axle shaft system to deliver power from front differential to front wheels. Both axle shafts are identical and interchangeable, 3-piece units consisting of outer Rzeppa joint, solid interconnecting shaft and inner tripod joint. Both Rzeppa joints and tripod joints are true Constant Velocity (CV) joint assemblies. Inner tripod joint allows for changes in axle shaft length through jounce and rebound travel of front suspension. Both inner CV joints are splined onto differential axle shafts and are retained on axle shaft by a snap ring located on axle shaft. Outer CV joints have stub shafts that are splined into wheel hub and are retained by a steel hub nut.

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Vehicle Application: Customer Concern: Tests/Procedures: Potential Causes: Diagnostic Codes: 2002 GAS, 2003 GAS, Chevrolet Silverado 1500 4.8L, Vin V, Eng Cfg V8, USA/Canada Chevrolet Silverado 1500 4.8L, Vin V, Eng Cfg V8 The engine runs, but lacks power when driving. Has codes P0101 and P0300. Scanner shows misfires all on the same side of the engine. 1. Check the catalytic converter, on the “suspect” bank of the engine, for a restricted (plugged) exhaust system to that side of the engine. 2. Disconnect both front O2 sensors, re-set the fuel trims and see if the problem goes away. 3. If gone with the O2 sensors disconnected, then swap the sensors side to side and see if the problem follows the O2 sensor. Plugged Exhaust System Oxygen Sensor P0101, P0300 2003 Chevrolet Tahoe 4.8L, GAS, Vin V 2003 Chevrolet Tahoe 5.3L, FLEX, Vin Z

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ISSUE Some 2003-2005 Explorer Sport Trac vehicles equipped with the Goodyear Wrangler RT/S, P255/70R16 109S AT OWL tire, may exhibit signs of feathering heel-toe wear on the inside or outside edges of the front tires. Tire noise may also be present during regular highway drive or when braking. ACTION Inspect the tires for feathering heel-toe wear. It may be necessary to rotate or replace tires and reset toe. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Visually inspect the front tire’s inside and outside shoulder ribs (Figure 1). 2. Measure the difference in tread depth of the leading edge compared to trailing edge, of the most-worn lug (figure 2). If the average difference in tread depth between leading and trailing edge is less than 2 mm, rotate the tires. If the average difference is more than 2 mm, replace the front tires. Also inspect the rear tires and replace if necessary. 3. Ensure that the camber and caster readings are within specification. 4. Set the total front toe (TFT) to 0.12 +/- 0.05 degrees (nominal). NOTE IT IS VERY IMPORTANT THAT THE TOE BE SET POSITIVE TO 0.12 +/- 0.05 DEGREES (NOMINAL). NOTE REFER TO WORKSHOP MANUAL SECTION 204-00 FOR ALIGNMENT PROCEDURES. REFER TO THE WARRANTY AND POLICY MANUAL FOR TIRE AND ALIGNMENT REIMBURSEMENT COVERAGE.

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Tools Required ^ J22912-01 Split-Plate Bearing Puller ^ J2619-01 Slide Hammer ^ J29369-1 Bushing and Bearing Remover ^ J29369-2 Bushing and Bearing Remover (2-3 inch) ^ J33791 Carrier Bushing Remover/Installer ^ J34011 Pilot Bearing Remover ^ J36598 Holding Fixture ^ J36599-A Side Bearing Nut Wrench ^ J36616 Axle Mount Bushing Remover/Installer ^ J36615 Side Bearing Nut Wrench ^ J8614-01 Flange and Pulley Holding Tool Inspection Procedure Perform the following before disassembling the axle: 1. Remove the fill plug from the axle. 2. Remove the drain plug from the axle. 3. Drain the axle lubricant. 4. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage. 5. Check the ring gear backlash. This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case. Determine the cause of the axle problem before disassembly, if possible. Disassembly Procedure 1. Remove the upper differential carrier assembly bushing by performing the following steps: 1.1. Install the J36616-2 (1), the J33791-1 (2), the thrust bearing (3), the J21474-18 (4), and the forcing screw as shown. 1.2. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J21474-18. 2. Remove the lower differential carrier assembly bushing by performing the following steps: 2.1. Install the J21474-18 (1), the thrust bearing (2), the J33791-1 (3), the J36616-2 (4), and the forcing screw as shown. 2.2. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J21474-18. 3. Remove the front axle actuator. 4. Remove the inner axle shaft housing to differential carrier assembly bolts.