Rear Axle Assemble (9.5 Inch Axle)

Rear Axle Assemble (9.5 Inch Axle)

Tools Required

- J 7818 Inner Bearing Race Installer
- J 8092 Universal Driver Handle � in-10
- J 8614-01 Flange and Pulley Holding Tool
- J 22306 Pinion Cup Bearing Installer-Rear
- J 22388 Pinion Oil Seal Installer-Rear
- J 24429 Side Bearing Backlash Spanner
- J 29709 Wheel Bearing Installer
- J 29713 Axle Seal Installer
- J 36614 Inner Pinion Bearing Installer






1. Install the outer pinion bearing cup using the J 22306 (2) and the J 8092 (1).






2. Install the inner pinion bearing cup using the J 22306 (1) and the J 8092 (2).
3. Determine the selective shim thickness for the pinion.






4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
5. Install the inner pinion bearing using the J 36614.

Press the bearing on until the cone seats on the pinion shim.

6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations Specifications.
8. Install the pinion into the axle housing.
9. Install the outer pinion bearing onto the pinion.






10. Install a new seal using the J 22388.
11. Apply sealant (GM P/N 12346004 or equivalent) to the splines of the pinion yoke.






12. Install the pinion yoke.

Align the marks made during removal.

Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

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.






15. Install the J 8614-01 onto the pinion yoke as shown.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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
Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

17. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations Specifications.






18. Place the differential case, with the bearing cups installed, into the axle housing.

Support the case in order to keep the case from falling out of the axle housing.






19. Install the bearing caps and the bolts.

Do not torque the bearing cap bolts at this time.

20. Turn the adjuster using the J 24429 until snug against the differential.
21. Adjust the differential side bearing preload.






22. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal.

Tighten
Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 lb in) greater than the rotating torque recorded during removal.

23. 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.
24. Adjust the backlash.
25. Perform a gear tooth contact pattern check.
26. Install the differential adjuster nut lock.
27. Install the differential adjuster nut lock bolt.

Tighten
Tighten the differential adjuster nut lock bolt to 26 Nm (19 lb ft).






28. Install the axle shaft bearing using the J 29709 (1) and the J 8092 (2).

Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.






29. Install the axle shaft seal using the J 29713.

Drive the tool into the bore until the axle shaft seal bottoms flush with the tube.






Important: Carefully insert the axle shaft in order to not damage the seal.

30. Install the axle shaft (1) into the housing (5).
31. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
32. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
33. On axles with a locking differential, keep the pinion shaft partially withdrawn.






34. On axles with a locking differential, place the lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
35. Pull the shaft flange outward in order to seat the lock in the differential gear.






36. Align the hole in the pinion shaft with the bolt hole in the differential case.
37. Install the new pinion shaft locking bolt.

Tighten
Tighten the pinion shaft locking bolt to 50 Nm (37 lb ft).






38. Install the rear axle housing cover (2) and a new gasket.
39. Install the rear axle housing cover bolts (1).

Tighten
Tighten the rear housing cover bolts in a crosswise pattern to 40 Nm (30 lb ft).

40. Fill the axle using the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations Specifications.






41. Install the fill plug.

Tighten
Tighten the fill plug to 33 Nm (24 lb ft).