Differential - Front Actuator Replacement
88chevy06Number: 88-168-4C
Section: 4C
Date: MARCH, 1988
Subject: FRONT AXLE ACTUATOR
Model and Year: 1988 K TRUCK
TO: ALL CHEVROLET DEALERS
If the front axle does not engage or disengages while the vehicle is operated in 4 high or 4 low and diagnosis indicates that replacement of the front axle actuator is necessary, use the following parts and instructions:
From start of production through the following VIN breakpoints.
Pontiac Production - JE169688
Fort Wayne Production - JZ224228
Oshawa Production - J1231643
Repair by replacing both the thermal actuator and the fork dampener assembly.
Use: Actuator Assembly P/N 26013495
Fork Damper Assembly P/N 26013507
Production began using the fork damper assembly with the vehicle identification number breakpoints listed above. After these VIN's repair with actuator assembly only.
Actuator Assembly P/N 26013495
The fork damper assembly reduces back pressure and the new actuator is a new part. Used together, these parts increase actuator life.
FIGURE 1:
SERVICE PROCEDURE
Thermal Actuator Replacement
Remove and disconnect
1. Disconnect electrical wire from black junction located on axle tube.
2. Unscrew actuator (Figure 1, item 16).
Install and connect
1. Install replacement actuator (Figure 1, item 16). Tighten to 22 N-m (16 ft.lbs.).
2. Connect wire to black junction on axle tube.
Fork Damper Assembly Replacement
Raise truck and support using suitable safety stands.
Remove or disconnect
1. Actuator connector.
2. Indicator light connector.
3. Drive axle to tube bolts.
4. Axle mounting nuts.
5. Nut from the idler arm.
6. Nut from pitman arm. Push the relay rod up and toward the front of the truck. Turn wheel out to loosen the drive shaft from the axle tube. Move axle shaft away from the axle tube and secure out of the way.
7. Stabilizer shaft link, if present.
8. Skid plate, if present.
9. Drain plug from the carrier and drain the axle lubricant.
10. Axle tube to carrier bolts.
11. Axle tube from carrier. Take care to keep the open end of the tube up.
12. Shift lever and fork. (Spring #13 in Figure 1 and clip #11 will not be in existing tube and are part of new fork damper assembly).
Install or connect
1. Shift lever, fork, spring and clip assembly into carrier case (Assembly part number 26013507). Install spring (#10 in Figure 1) on shift lever. Clean mating surfaces of the axle tube and carrier assembly. Remove all oil and grease. Use carburetor cleaner or equivalent. Apply a bead of sealer (GM P/N 1052942, Loctite 518, or equivalent) to the tube sealing surface.
2. Axle tube to carrier.
3. Axle tube to carrier bolts and tighten to 40 N-m (30 ft lbs).
4. Drive shaft to axle shaft.
5. Drive shaft to axle shaft bolts and tighten to 80 N-m (59 ft.lbs.).
6. Axle mounting nuts with washers. Tighten to 80 N-m (59 ft.lbs.).
7. Relay rod to idler arm and pitman arm.
8. Idler arm washer and nut.
9. Pitman arm washer and nut. Tighten pitman arm and idler arm nuts to 54 N-m (40 ft.lbs.).
10. Stabilizer shaft link, if present.
11. Actuator connector.
12. Indicator connector.
13. Drain plug and the washer. Tighten plug to 32 N-m (24 ft.lbs.).
14. New lubricant. Refer to "Specifications" 1988 C/K Pick-Up Truck Service Manual ST375-88.
15. Filler plug. Tighten plug to 32 N-m (24 ft.lbs.).
16. Skid plate, if present.
17. Skid plate torx head screws. Tighten screws to 34 N-m (25 ft.lbs.).
Lower truck.
For warranty replacement of the thermal actuator only use:
Labor Op: F0025 Time: 0.3 Hrs
For warranty replacement of the thermal actuator and shift lever assembly use:
Labor Op: T7525 Time: 1.1 Hrs.
FIGURE 1:
1. Shaft
2. Deflector
3. Seal
4. Bearing
5. Tube
6. Bolt
7. Thrust Washer
8. Retaining Ring
9. Carrier Connector
10. Spring
11. Clip
12. Shift Fork
13. Damper Spring
14. Shift Shaft
15. Indicator Switch
16. Solenoid
20. Shim
21. Differential Pilot Bearing
22. Sleeve
23. Output Shaft
25. Plug
26. Washer
27. Pin
28. Bolt
29. Carrier Case
30. Bearing
31. Insert
32. Sleeve
33. Side Bearing
34. Bolt
35. Differential Case
36. Pin
37 Ring and Pinion Gears
38. Shim
39. Bearing
40. Spacer
41. Bearing
42. Seal
43. Deflector
44. Flange
45. Washer
46. Nut
48. Bushing
51. Lock
52. Shaft
53. Thrust Washer
54. Side Gear
55. Thrust Washer
56. Differential Pinion Gear
58. Bolt
59. Shaft
60. Vent Plug