8.25 S4WD and 9.25 Axles

Differential Carrier Assembly - Final Assembly (8.25 S4WD and 9.25 Axles)
^ Tools Required
- J 29710 Differential Side Bearing Installer
- J 22761 Differential Side Bearing Installer
- J 22833 Housing Driver Gear Installer
- J 36600 Output Shaft Seal Installer
- J 33842 Pilot Bearing Installer
- J 36616 Axle Mount Bushing Remover/Installer





1. Bend the differential adjuster nut lock tabs over the differential adjuster nut sleeves, 8.25 inch axle -both sides, 9.25 inch axle - right side.
2. Install the differential adjuster nut lock, 9.25 inch axle - left side.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the differential adjuster nut lock bolt.
^ Tighten the differential adjuster lock nut bolt to 20 Nm (15 lb ft).
4. Remove the differential carrier assembly bolts.
5. Remove the right differential carrier case half.
6. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
7. Apply a bead of sealer, GM P/N 1052942 or the equivalent, to one differential carrier case half sealing surface.
8. Install the right differential carrier case half.
9. Install the differential carrier case bolts.
^ Tighten the differential carrier case bolts to 47 Nm (35 lb ft).
10. Lubricate the clutch shaft pilot bearing with axle lubricant.





11. Install the clutch shaft pilot bearing using the J 33842.





12. Install the clutch shaft to the differential carrier.





13. Install the differential carrier bushings using the J 36616.
14. Install the vent plug. Use a small amount of sealer, GM P/N 1052942 or the equivalent, on the threads.





15. Install the new axle shaft seal (26) using the J 36600, 8.25 inch axle, or the J 22833, 9.25 inch axle.
16. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear.
17. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.





18. Install the right side bearing by performing the following steps:
18.1. Install the inner axle shaft housing into a vise.
Clamp only on the mounting flange of the inner axle shaft housing.
18.2. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).





19. Install the right side inner axle shaft seal by performing the following steps:
^ Install the inner axle shaft housing into a vise.
Clamp only on the mounting flange of the inner axle shaft housing.
^ Install the new axle shaft seal using the J 36600, 8.25 inch axle, or the J 22833, 9.25 inch axle.
20. Install the inner axle shaft into the inner axle shaft housing.
Carefully tap the inner axle shaft into place with a soft-faced mallet.





Important: Use chassis grease to in order to hold the thrust washer in place.

21. For the 8.25 inch axle, perform the following steps:
21.1. Install the thrust washer (5) into the inner axle shaft housing. Ensure the tabs on the thrust washer (5) align with the slot in the inner axle shaft housing (4).
21.2. Install the new retainer ring (7) onto the clutch gear (6).
21.3. Install the clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer.
21.4. Determine the clutch gear shim thickness.
21.5. Install the clutch gear shim (9).
21.6. Install the clutch sleeve (8).
21.7. Assemble the following components to the clutch fork shaft (14):
21.7.1. The clutch fork outer spring (13)
21.7.2. The clutch fork (12)
21.7.3. The clutch fork shaft retainer ring (11)
21.8. Install the clutch fork assembly (14, 13, 12, 11).
21.9. Install the clutch fork inner spring (10) into the differential carrier case.





Important: Use chassis grease to in order to hold the thrust washer in place.

22. For the 9.25 inch axle, perform the following steps:
22.1. Install the thrust washer (5) into the inner axle shaft housing. Ensure the tabs on the thrust washer (5) align with the slot in the inner axle shaft housing (4).
22.2. Install the second thrust washer (6) into the inner axle shaft housing.
22.3. Install the new retainer ring (7) onto the inner axle shaft (1).
22.4. Determine the clutch gear shim thickness.
22.5. Install the clutch gear shim (9).
22.6. Install the clutch sleeve (8).
22.7. Assemble the following components to the clutch fork shaft (14):
22.7.1. The clutch fork outer spring (13)
22.7.2. The clutch fork (12)
22.7.3. The clutch fork shaft retainer ring (11)
22.8. Install the clutch fork assembly (14, 13, 12, 11).
22.9. Install the clutch fork inner spring (10) into the carrier case.
23. Apply sealant, GM P/N 1052942 or equivalent, to the inner axle housing to differential carrier sealing surface.
24. Install the inner axle shaft housing to the differential carrier case.
25. Install the inner axle shaft housing bolts.
^ Tighten the inner axle shaft housing bolts to 40 Nm (30 lb ft).
26. Install the drain plug and the washer.
27. Install the fill plug and the washer.
^ Tighten the drain plug and the fill plug to 33 Nm (24 lb ft).





28. Apply sealant, GM P/N 12346004 or equivalent, to the threads of the front axle actuator.
29. Install the front drive axle actuator.
^ Tighten the front drive axle actuator to 20 Nm (15 lb ft).