1942 - 1947 CHEVROLET SHOP MANUAL

Section 4  - Rear Axle, Universal Joints & Springs

4-9
8.   Install the housing cover, using a new cork gas-ket and fill the differential with 3-1/2 pints of the proper hypoid lubricant.
9.   Pour approximately one-half pint of transmis­sion lubricant into the front end of the pro­peller shaft housing to provide initial lubrica­tion of the propeller shaft bushings.
To Replace the Rear Axle Assembly
Reverse the operation shown under the removal of the rear axle. Care should be taken to see that all cotter pins are assembled and securely bent over. The "U" bolts holding the springs to the spring seats must be drawn up securely.
When connecting the brake cables make sure that all of the play is out of the cables before con­necting and tightening check nuts at idler lever.
After replacement of the rear axle it will be necessary to bleed the brake lines at ALL FOUR WHEELS, as described in the "Brake Section" of this Manual.
REAR AXLE ASSEMBLY 1/2 AND ALL 3/4-TON TRUCKS
The rear axles used on the 1/2, and all 3/4-ton truck models are the same hypoid type as the pas­senger car but their construction is much heavier. The lubrication of the front pinion (thrust) bear­ing is accomplished by an oil passage drilled in the differential carrier for oil flow to this bearing. An oil retainer is mounted in the carrier ahead of the pinion rear bearing to retard the return of the oil to the differential, thereby maintaining a bath of oil for the front pinion bearing.
REPAIR OPERATIONS
The repair operations for these rear axles are the same as those on the passenger car with the following exceptions:
Pinion Assembly—1/2-Ton Model
When assembling the pinion and shaft assembly. first install the roller bearing and lock it in place with the lock ring. Then thread the pinion front bearing oil retainer over the shaft with the bevel of the large diameter of the retainer toward the pinion. Coat the beveled surface of the pinion bear­ing lock sleeve with rear axle lubricant and install it with the bevel side toward the pinion, then assemble the front pinion (thrust) bearing retain­ing nut. All other pinion and propeller shaft oper­ations are the same as those for the passenger car rear axle.
Pinion Assembly—3/4-Ton Models
The rear axle on the 3/4-ton models is of the Hotchkiss drive type, incorporating the open pro­peller shaft and universal joints, and rear spring seats welded to the rear axle housing. However, the overhaul and repair operations for the differ­ential and axle shafts, etc., are the same as for the 1/2-ton truck rear axle.
The end of the differential carrier is machined for the spring loaded oil seal which engages the ground hub of the universal joint rear yoke. An oil and dust deflector is pressed on the outer diameter of the universal joint yoke.
The drive pinion shaft is threaded at its for­ward end for the nut which attaches the universal joint rear yoke to the shaft.
When assembling the drive pinion to the differ­ential carrier, the universal joint rear yoke must be installed and its retaining nut tightened securely before attempting to make any ring gear and pinion adjustment.
Before installing a new pinion bearing retainer oil seal it should be soaked thoroughly in light engine oil.
Axle Shafts
The axle shafts for the 1/2 and 3/4 ton truck models are slightly longer than those for the pas­senger car. In addition, they are heavier and larger in diameter in the unfinished part of the shaft. When making axle shaft replacements care must be taken to select the proper axle shaft for the job involved.
Axle Shaft Spacers
There are three sizes of axle shaft spacers serv­iced for the 1/2 and all 3/4-ton truck rear axles. The dimensions of these spacers are:
Narrow—1.1485" Wide Across Ground Surfaces.
Wide
1.1575" Wide Across Ground Surfaces.
1.1675" Wide Across Ground Surfaces.
These three dimensions are obtained with the use of only two axle shaft spacers, the 1.1485" spacer being ground on only two sides, while the larger spacer is ground on all four sides to obtain both the 1.1575" and the 1.1675" dimensions.
REAR AXLE ASSEMBLY l-1/2-TON TRUCKS
Construction
The full-floating type rear axle used on all 1-1/2 ton trucks is so constructed that the axle shafts can be removed without removing the truck load or jacking up the rear axle. This axle is equipped with a hypoid ring gear and pinion, Fig. 15.

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