Differential Carrier Assembly - Final Assembly

DIFFERENTIAL CARRIER ASSEMBLY - FINAL ASSEMBLY

TOOLS REQUIRED
- J 22833 Housing Driver Gear Seal Installer
- J 36609 Axle Tube Bearing Installer
- J 45755 Front Axle Bushing Remover/Installer - 9.25 inch Axle




1. Bend the right side differential adjuster nut lock tab over the differential adjuster nut sleeve.




2. Install the differential adjuster nut lock.

NOTE: Refer to Fastener Notice in Service Precautions.




3. Install the differential adjuster nut lock bolt.

Tighten
Tighten the differential adjuster lock nut bolt to 20 N-m (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 (Canadian P/N 10953466) 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
Tighten the differential carrier case bolts to 47 N-m (35 lb ft).




10. Install the upper differential carrier assembly bushing into the upper differential carrier assembly bushing bore.
11. Install the J 45755-2 (2), J 45755-1 (3), and the forcing screw, bearing and washers (1) over the differential carrier assembly bushing as shown.
12. Press the bushing into the differential carrier assembly bushing bore using the J 45755.

NOTE: Refer to Component Fastener Tightening Notice in Service Precautions.




13. Install the differential carrier hole plug.
Use a small amount of sealer, GM P/N 12346004 (Canadian P/N 10953480) or the equivalent, on the threads

Tighten
Tighten the differential carrier hole plug to 28 N-m(21 lb ft).




14. Install the new left side axle shaft seal using the J 22833.
15. Install the left side 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.
16. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.




17. Install the right side inner axle shaft bearing by performing the following steps:
17.1. Install the inner axle shaft housing into a vise.
17.2. Install the bearing with the square shoulder in using the J 36609 (1) and the J8092 (2).




18. Install the right side inner axle shaft seal by performing the following steps
- Install the inner axle shaft housing into a vise
- Install the new axle shaft seal using the J22833




19. Install the inner axle shaft into the inner axle shaft housing
Carefully tap the inner axle shaft into place with a soft-faced mallet
20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to the inner axle housing to differential carrier sealing surface.




21. Install the inner axle shaft housing to the differential carrier case




22. Install the inner axle shaft housing bolts.

Tighten
Tighten the inner axle shaft housing bolts to 40 N-m (30 lb ft).

NOTE: Refer to Fastener Notice in Service Precautions.

23. Install the drain plug and the washer.

Tighten
Tighten the drain plug to 33 N-m (24 lb ft).

24. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle.
25. Install the fill plug and the washer.

Tighten
Tighten the fill plug to 33 N-m (24 lb ft).