Installation Procedure

INSTALL OR CONNECT
^ Tools Required:
- J 8107-4 Differential Side Bearing Remover Plug
- J 8092 Driver Handle
- J 37758 Pinion Outer Race Installer
- J 37759 Pinion Inner Bearing Race Installer
- J 35138 Side Gear Thrust Play Tool
- J 38891 Wheel Speed Sensor Ring Installer
- J 38890 Differential Torque Check Tool





1. Rear wheel antilock (ABS) speed sensor exciter ring onto left differential case half using J 38891 exciter ring installer and J 8107-04. Place the exciter ring inside the J 38891 on a hydraulic press. Then, center the left differential case half in the exciter ring with J 8107-4 side in the left axle shaft bore and slowly press the left differential case half evenly into the exciter ring.

Important: Observe hydraulic pressure gage during speed sensor exciter ring installation. Pressure exerted on the exciter ring should not exceed 500 kg (1102 lbs.). If pressure higher than specified is needed to install the left differential case into the exciter ring, the two components may be misaligned. Reposition the left differential case in the exciter ring so that pressure will be even around the perimeter and repeat the installation procedure.

Inspect





- Left differential case face to make sure the speed sensor exciter ring is flush with or higher than the left differential case.
2. Rear wheel speed sensor, secure with rear wheel speed sensor bolt (if equipped).
- Tighten rear wheel speed sensor bolt to 23 Nm (17 ft. lbs.).





3. Right side gear and washers, differential pinion gears and washers, cross shafts and pinion cross shaft joint in right differential case.

Measure
^ Tool Required:
- J 8001 Dial Indicator Set





^ Right differential side gear end play using J 8001. Insert fingers through the bottom openings of the right differential case half and move the right differential side gear up and down while observing the J 8001. Right differential side gear end play should measure 12 to 37 mm (O.OO5 to O.O14 inch). If right differential side gear end play is too high or low, replace the selective shim with the appropriate size to obtain correct end play.





4. Cross shaft roll pins into right differential case half. Roll pin ends should be flush with the right differential case surface.





5. Left differential side gear and washers into right differential case.





6. Left differential case half and ring gear to right differential case half; secure with ten bolts.
- Tighten ring gear bolts to 90 Nm (65 ft. lbs.).

Measure
^ Tools Required:
- J 8001 Dial Indicator Set
- J 35138 Side Gear Thrust Play Tool
- J 38890 Differential Torque Check Tool





1. Left differential side gear end play using J 8001 and J 35138. Insert the J 35138 in through the left axle shaft differential case bore and adjust until the J 35138 has a firm grasp on the left differential side gear. Then, move J 35138 up and down while observing the J 8001. Left differential side gear end play should measure 12 to 37 mm (0.005 to 0.014 inch). If left differential side gear end play is too high or low, replace the selective shim with the appropriate size to obtain correct end play.





2. Side gear preload using J 38890. Insert the J 38890 into either side bearing and with a torque wrench, measure the side bearing preload. Maximum side gear preload should be 2.4 Nm (21 inch lbs.). If preload exceeds specification, inspect side and differential pinion gears for foreign material or damage.

Important: After correct end play and preload has been obtained, remove the ring gear bolts and apply GM P/N 12345493, or equivalent, to the threaded portion of each ring gear bolt and install into differential case assembly.

- Tighten:
^ Ring gear bolts to 90 Nm (65 ft. lbs.).





^ Right differential side bearing on the right side of the differential case assembly using J 37758 with J 8092. Place the differential case assembly on a hydraulic press and using J 8107-4 for support. Then, using the J 37759 with the J 8092, place the right differential side bearing on the right differential case with the taper side up and slowly press the right differential side bearing onto the right differential case.





- Left differential side bearing to the left side of the differential case assembly using J 37758 with J 8092 and J 8107-4. Place the differential case assembly on a hydraulic press with J 8107-4 for support and to protect the right differential side bearing. Then, using the J 37758 with the J 8092, place the left differential side bearing on the left differential case with the taper side up and slowly press the left differential side bearing evenly onto the left differential case.





- Inner pinion bearing race using J 37759 with J 8092. Place the differential carrier on a hydraulic press and position the inner pinion bearing race over its bore. Then, using the J 37759 inner with the J 8092, slowly press the inner pinion bearing race evenly into the differential carrier.





- Outer pinion bearing race using J 37758 with J 8092. Place the differential carrier on a hydraulic press and position the outer pinion bearing race over its bore. Then, using the J 37758 with the J 8092, slowly press the outer pinion bearing race evenly into the differential carrier.