Differential Carrier Assembly - Assemble

Differential Carrier Assembly - Assemble
^ Tools Required
- J 8092 Universal Driver Handle - 3/4 in - 10
- J 8614-01 Flange and Pulley Holding Tool
- J 35512 Inner Pinion Bearing Installer
- J 36366 Pinion Oil Seal Installer
- J 36598 Holding Fixture
- J 36599-A Side Bearing Nut Wrench
- J 36603 Side Bearing Cup Installer
- J 36609 Axle Tube Bearing Installer
- J 36612 Output Shaft Bearing Installer
- J 36614 Inner Pinion Bearing Installer
- J 36615 Side Bearing Nut Wrench (9.95 inch axle)





1. Install the pinion bearing cups into the differential carrier assembly. Refer to Pinion Bearing Cup Installation.
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 J 35512, 8.25 inch axle, or the J 36614, 9.25 inch axle.
4. Install the new collapsible spacer onto the pinion gear.
5. Install the J 36598 into a vise.
6. Install the left differential carrier case half into the J 36598 and the J 36598-6, 8.25 inch axle, or the J 36598, 9.25 inch axle.
7. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations.
8. Install the outer pinion bearing into the left differential carrier case half.





9. Install the pinion oil seal using J 36366.
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 Replacement 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 the following 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 pinon 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 J 8614-01.
^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut in order to seat the bearings.
17. Remove the J 8614-01.
18. Measure the rotating torque of the pinion using an inch-pound torque wrench.
Specification
^ 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, reinstall the J 8614-01 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 J 8614-01.
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 sleeve using the J 36612 (2) and the J8092(1), 8.25 inch S4WD axle - left and right sides, 8.25 inch F4WD axle - left side, 9.25 inch axle - right side.
24. Install the axle shaft bearing into the differential adjuster nut sleeve using the J 36609 and the J 8092, 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 J 36609 and the J 8092, 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 J 36603 (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 J 36599-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 ft. lbs.).
31. Install the differential carrier assembly into a vise.





32. Turn the right side differential adjuster nut sleeve clockwise 1 1/2 revolutions using the J 36599-A.





33. For the 8.25 inch axle, turn the left side differential adjuster nut sleeve clockwise using the J 36599-A in order to preload the differential side bearings against the differential side bearing cups.
^ Tighten the differential adjuster nut to 75 Nm (55 ft. lbs.).





34. For the 9.25 inch axle, turn the left side differential adjuster nut clockwise using the J 36615 in order to preload the differential side bearings against the differential side bearing cups.
^ Tighten the differential adjuster nut to 75 Nm (55 ft. lbs.).
35. Rotate the pinion several times in order to seat the pinion and differential side bearings.
36. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench.
Specification
^ The rotating torque of the pinion and differential assembly should be 3.4 - 6.2 Nm (30 - 55 inch lbs.) for new bearings or 2.8 - 5.1 Nm (25 - 45 inch lbs.) for used bearings.





37. 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, adjust the differential side bearing preload using the following steps:
37.1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
37.2. Using the J 36599-A or the J 36615, turn the left and the right side differential adjuster nut sleeves in or clockwise one notch.
37.3. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.
37.4. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential assembly is not within specifications, continue to Tighten the left and right side 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
38. 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, adjust the differential side bearing preload using the following steps:
38.1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
38.2. Using the J 36599-A or the J 36615, turn the left and the right side differential adjuster nut sleeves out or counterclockwise one notch.
38.3. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.
38.4. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side 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. Once the specified rotating torque is obtained, rotate the pinion several times to ensure the bearings have seated.
Recheck the rotating torque and adjust if necessary.
40. Measure the drive pinion to ring gear backlash. Refer to Backlash Inspection and Adjustment.