GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Avalanche - 4WD 🢒 Driveline/Axle 🢒 Front Drive Axle 🢒 Front Differential Drive Pinion Gear Bearing Cup Installation

Front Differential Drive Pinion Gear Bearing Cup Installation 8.25/9.25 Inch Axles w/J 36598

Tools Required

J 36598 Holding Fixture

  1. Before assembly, apply axle lubricant to the pinion bearing cups. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  2. Install the J 36598 into a vise.

    3. Object Number: 680579 Size: SH
  3. Install the left differential carrier case half into the J 36598 and the J 36598-6, 8.25 inch axle, or the J 36598  (1), 9.25 inch axle.

    4. Tighten the attaching bolts securely.

  4. Install the J 36598-3, 8.25 inch axle, or the J 36598-4, 9.25 inch axle (2), onto the forcing screw of the J 36598 .
  5. Install the outer pinion bearing cup into the differential carrier case.
  6. Install the J 36598-3, 8.25 inch axle, or the J 36598-4, 9.25 inch axle (2) onto the outer pinion bearing cup.

    7. Rotate the J 36598-3 or the J 36598-4 and the outer pinion bearing cup several time in order to seat the outer pinion bearing cup evenly within the outer pinion bearing cup bore.

  7. Install the outer pinion bearing cup into the differential carrier case half by holding the forcing screw of the J 36598 and turning the handle counterclockwise.

    8. Inspect the position of the outer pinion bearing cup as it is being installed into the outer pinion bearing cup bore to ensure the bearing cup is being installed evenly. If the pinion bearing cup is not being installed evenly, loosen the J 36598 and remove the outer pinion bearing cup. Reposition the outer pinion bearing cup over the outer pinion bearing cup bore and re-install.

  8. Remove the J 36598-3 or the J 36598-4 from the forcing screw of the J 36598 .

    9. Object Number: 890240 Size: SH
  9. Install the J 36598-15 (2) into the outer pinion bearing cup.
  10. Install the inner pinion bearing cup into the inner pinion bearing cup bore.

    11. Object Number: 890237 Size: SH
  11. Place the J 36598-3, 8.25 inch axle, or the J 36598-4, 9.25 inch axle (2), over the inner pinion bearing cup.
  12. Extend the forcing screw of the J 36598  (1) through the J 36598-15 and thread it into the J 36598-3 or the J 36598-4 (2) until fully seated.
  13. Rotate the J 36598-3 or the J 36598-4 several times in order to ensure the inner pinion bearing cup is evenly seated and not mis-aligned in the bore.
  14. Install the inner pinion bearing cup into the differential carrier case half by holding the forcing screw of the J 36598 and turning the handle clockwise.

    15. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being installed evenly. If the pinion bearing cup is not being installed evenly, loosen the J 36598 and remove the inner pinion bearing cup. Reposition the inner pinion bearing cup over the inner pinion bearing cup bore and re-install.

  15. Remove the J 36598-3 or the J 36598-4 and the J 36598-15.
  16. Remove the differential carrier case.
  17. Remove the J 36598 from the vise.
  18. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment .

Front Differential Drive Pinion Gear Bearing Cup Installation 9.25 Inch Axle w/J 45754

Tools Required

J 45754 Pinion Bearing Race Remover/Installer - 9.25 in Axle

  1. Before assembly, lubricate the following parts with axle lubricant. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    2. • The pinion bearings
    • The pinion and the differential gears
    • The thrust washers
    • The pinion bearing cups

    Object Number: 866069 Size: SH
  2. Install the outer pinion bearing cup into the outer pinion bearing cup bore.

    3. Object Number: 866070 Size: SH
  3. Install the J 45754-1 over the outer pinion bearing cup.

    4. Object Number: 866182 Size: SH
  4. Install the forcing screw (1), the J 45754-2 (2) into the inner pinion bearing cup bore.
  5. Attach the forcing screw to the J 45754-1.

    6. Slowly turn the forcing screw until the J 45754-1 is evenly seated over the outer pinion bearing cup bore and the J 45754-2 with the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore.

  6. Turn the forcing screw clockwise slowly in order to draw the outer pinion bearing cup into the outer pinion bearing cup bore.

    7. Inspect the position of the outer pinion bearing cup as it is being drawn into the outer pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45754 and the outer pinion bearing cup and reposition the outer pinion bearing cup.

  7. Tighten the forcing screw until the outer pinion bearing cup is seated in the outer pinion bearing cup bore.
  8. Remove the J 45754 .

    9. Object Number: 866071 Size: SH
  9. Install the inner pinion bearing cup onto the J 45754-2 (2) and the forcing screw (1).
  10. Install the J 45754-2 (2), the forcing screw (1), and the inner pinion bearing cup into the pinion bearing cup bore.

    11. Object Number: 866070 Size: SH
  11. Install the J 45754-1 over the outer pinion bearing cup.
  12. Attach the forcing screw to the J 45754-1.

    13. Slowly turn the forcing screw until the J 45754-1 is evenly seated over the outer pinion bearing cup bore and the J 45754-1 with the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore.

  13. Turn the forcing screw clockwise slowly in order to draw the inner pinion bearing cup into the inner pinion bearing cup bore.

    14. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45754 and the inner pinion bearing cup and reposition the inner pinion bearing cup.

  14. Tighten the forcing screw clockwise until the inner pinion bearing cup is seated in the inner pinion bearing cup bore.
  15. Remove the J 45754 .
  16. Measure the pinion depth and determine the selectable pinion shim thickness. Refer to Pinion Depth Adjustment .

Front Differential Drive Pinion Gear Bearing Cup Installation 8.25 Inch Axle w/J 45858

Tools Required

J-45858 Pinion Bearing Race Remover/Installer - 8.25 in Axle

  1. Before assembly, lubricate the following parts with axle lubricant. Use the proper fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers.
    2. • The pinion bearings
    • The pinion and the differential gears
    • The thrust washers
    • The pinion bearing cups

    Object Number: 1486596 Size: SH
  2. Install the J 45858-3 (3), the thrust bearing and the washer (2), and the J 45858-6 (1) over the outer pinion bearing cup bore.

    3. Object Number: 1486589 Size: SH
  3. Install the inner pinion bearing cup and the J 45858-2 (4) to the J 45858-6 (1).

    4. Slowly turn the J 45858-6 until the inner pinion bearing cup is evenly seated over the inner pinion bearing cup bore.

  4. Turn the J 45858-6 clockwise slowly in order to draw the inner pinion bearing cup into the inner pinion bearing cup bore.

    5. Inspect the position of the inner pinion bearing cup as it is being drawn into the inner pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J-45858 and the inner pinion bearing cup and reposition the inner pinion bearing cup.

  5. Tighten the J 45858-6 until the inner pinion bearing cup is seated in the inner pinion bearing cup bore.
  6. Remove the J-45858 .

    7. Object Number: 1486578 Size: SH
  7. Install the outer pinion bearing cup and the J 45858-1 over the outer pinion bearing cup bore.

    8. Object Number: 1486587 Size: SH
  8. Install the thrust bearing and the washer (2), the J 45858-6 (1), and the J 45858-2 (3) as shown.
  9. Slowly turn the J 45858-6 until the outer pinion bearing cup is evenly seated over the outer pinion bearing cup bore and the J 45858-2 is evenly seated within the inner pinion bearing cup.
  10. Turn the J 45858-6 clockwise slowly in order to draw the outer pinion bearing cup into the outer pinion bearing cup bore.

    11. Inspect the position of the outer pinion bearing cup as it is being drawn into the outer pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J-45858 and the outer pinion bearing cup and reposition the outer pinion bearing cup.

  11. Tighten the forcing screw until the outer pinion bearing cup is seated in the outer pinion bearing cup bore.
  12. Remove the J-45858 .
  13. Measure the pinion depth and determine the selectable pinion shim thickness. Refer to Pinion Depth Adjustment.