Assemble
Differential Carrier Assembly - AssembleTools Required
^ J8092 Universal Driver Handle -- 3/4 inch - 10
^ J8614-01 Flange and Pulley Holding Tool
^ J35512 Inner Pinion Bearing Installer
^ J36366 Pinion Oil Seal Installer
^ J36598 Holding Fixture
^ J36599-A Side Bearing Nut 'Wrench
^ J36603 Side Bearing Cup Installer
^ J36609 Axle Tube Bearing Installer
^ J36612 Output Shaft Bearing Installer
^ J36614 Inner Pinion Bearing Installer
^ J36615 Side Bearing Nut Wrench (9.25 inch axle)
1. Install the pinion bearing cups into the differential carrier assembly.
2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
3. Install the inner pinion bearing onto the pinion gear using the J35512, 8.25 inch axle, or the J36614, 9.25 inch axle.
4. Install the new collapsible spacer onto the pinion gear.
5. Install the J36598 into a vise.
6. Install the left differential carrier case half into the J36598 and the J36598-6, 8.25 inch axle, or the J36598, 9.25 inch axle.
7. Lubricate the pinion bearings with axle lubricant.
8. Install the outer pinion bearing into the left differential carrier case half.
9. Install the pinion oil seal using J36366.
10. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke.
12. Install the pinion yoke.
Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions.
13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
14. Install the washer and a new pinion nut.
If the new pinion nut cannot be installed, perform these steps in order to seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed:
14.1. Remove the pinion nut washer.
14.2. Install the old pinion nut,
14.3. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed.
14.4. Remove the old pinion nut.
14.5. Install the pinion nut washer
14.6. Install the new pinion nut.
15. Install the J8614-01 onto the pinion yoke as shown.
Notice: Refer to Fastener Notice in Service Precautions.
Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
16. Tighten the pinion nut while holding the J8614-01.
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
17. Remove the J8614-01.
18. Measure the rotating torque of the pinion using an inch-pound torque wrench.
The rotating torque of the pinion should be 1.0 - 2.3 Nm (10 - 20 inch lbs.) for used bearings, or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings.
19. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, re-install the J8614-01 and continue to tighten the pinion nut.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the torque recorded during removal for used bearings or 1.7 - 3.4 Nm (15 - 30 inch lbs.) for new bearings.
20. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.
Recheck the rotating torque and adjust if necessary.
21. Remove the J8614-01.
22. Assemble the differential adjuster nut into the differential nut sleeve until fully seated, 8.25 inch axle - left and right sides, 9.25 inch axle, right side.
23. Install the axle shaft bearings into the differential adjuster nut sleeves using the J36612 (2) and the J8092 (1), 8.25 inch axle - left and right sides, 9.25 inch axle - right side.
24. Install the axle shaft bearing into the differential adjuster nut sleeve using the J36609 and the J8092, 9.25 inch axle - left side.
25. Install the differential adjuster nut assembly and new adjuster lock nut tabs into the differential carrier case using the J36609 and the J8092, 8.25 inch axle - left and right sides, 9.25 inch axle - right side.
26. Install the differential adjuster nut assembly into the differential carrier case, 9.25 inch axle -left side.
27. Install the differential case side bearing cups to the differential carrier case using the J36603 (2) and the J8092 (1), 8.25 inch axle - left and right sides, 9.25 inch axle-right side.
28. Install the differential case assembly into the left differential carrier case half.
29. Install the right differential carrier case half to the left differential carrier case half.
Do not use sealer at this time.
If the carrier case halves do not make complete contact, use the J36599-A in order to back out the right differential adjuster nut sleeve until the differential carrier case halves make contact.
30. Install the differential carrier case bolts.
Tighten the differential carrier case bolts to 47 Nm (35 lb ft).
31. Install the differential carrier assembly into a vise.
32. For the 8.25 inch axle, turn the left differential adjuster nut sleeve clockwise using the J36599-A until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
33. For the 8.25 inch axle, turn the right differential adjuster nut sleeve clockwise using the J36599-A until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
34. For the 9.25 inch axle, turn the differential adjuster nut clockwise using the J36615 until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
35. For the 9.25 inch axle, turn the right differential adjuster nut sleeve clockwise using the J36599-A until the differential adjuster nut sleeve contacts the differential side bearing and can no longer be turned.
36. Rotate the pinion several times in order to seat the bearings.
37. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.
The rotating torque of the pinion and differential assembly should be 2.8 - 5.1 Nm (25 - 45 inch lbs.) for used bearings, or 3.4 - 6.2 Nm (30 - 55 inch lbs.) for new bearings.
38. If the rotating torque measurement is below 2.8 Nm (25 inch lbs.) for used bearings, or 3.4 Nm (30 inch lbs.) for new bearings, tighten the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
39. If the rotating torque measurement is above 5.1 Nm (45 inch lbs.) for used bearings, or 6.2 Nm (55 inch lbs.) for new bearings, loosen the differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
40. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.
Recheck the rotating torque and adjust if necessary.
41. Measure the drive pinion to ring gear backlash.